Difficulties in Aftermarket Data Release

1. Difficulties in Aftermarket Data Release OEM and Aftermarket ConcernsScott Bolt – Chief Engineer MAHLE Test Systems 19 April 2012

2. Worldwide Locations MAHLE Overview • Germany • Albershausen • Alzenau • Barsinghausen • Brattendorf • Eislingen/Fils • Fellbach • Flintbek • Gaildorf • Hamburg • Leibertingen • Lorch • Markgröningen • Öhringen • Plettenberg • Roßwein • Rottweil • Schorndorf • Stuttgart • Wölfersheim • Wustermark • Zell im Wiesental • Great Britain • Bathgate • Kilmarnock • Northampton • Rugby • Stoke-on-Trent • Telford • Wellingborough • Worcester • Netherlands • Alkmaar • Lochem • USA • Ann Arbor (MI) • Atlantic (IA) • Farmington Hills (MI) • Franklin (KY) • McConnelsville (OH) • Morristown (TN) • Murfreesboro (TN) • Muskegon (MI) • Novi (MI) • Nowata (OK) • Olive Branch (MS) • Russellville (AR) • St. Johns (MI) • Trumbull (CT) • Winterset (IA) • Canada • Niagara-on-the-Lake • Tilbury • China • Changchun • Chongqing • Guangzhou • Macheng • Nanjing • Shanghai • Tianjin • Yingkou • France • Chavanod • Dardilly • Décines • Ingersheim • Orange • Poissy • Rungis • Seboncourt • Korea • Hwasung • Ulsan • Poland • Krotoszyn • Spain • Alcalá de Henares/Madrid • Vilanova I la Geltrú • Austria • Mattighofen • Rankweil • St. Michael ob Bleiburg • Vöcklabruck • Wolfsberg • Japan • Fukushima • Ibaraki • Kawagoe • Okegawa • Tochigi • Tokyo • Tsuruoka • Yamagata • Mexico • Aguascalientes • Lerma • Naucalpan • Ramos Arizpe • Santa Catarina • Portugal • Murtede • Switzerland • Grenchen • Slovakia • Dolný Kubí • Italy • Bomasco • LaLoggia • Saluzzo • Trento • Romania • Timisoara • Philippines • Cavite • Argentina • El Talar/Buenos Aires • Rafaela • Turkey • Gebze • Izmir • Konya • Thailand • Bangkok • Samutprakarn • Brazil • Indaiatuba • Itajubá • Jundiai • Limeira • Mogi Guaçu • Queimados • São Bernardo do Campo • India • Gurgaon • Maraimalainager/Chennai • Parwanoo • Pithampur • Pune • Production locations • R&D centers • April 2008 • Australia • Laverton North/Melbourne © MAHLE

3. Worldwide Research - Development - Testing Around the world, approximately 3,000 development engineers and technicians are working on future concepts, products and systems for ongoing development of vehicular innovation. Stuttgart Detroit (Farmington Hills) Northampton Tokyo (Okegawa) 1998 Shanghai 2004 Detroit (Novi) 2002 Tokyo (Kawagoe) São Paulo Jundiaí 2004 2006 2001 1997 2008 4 © MAHLE

4. MAHLE Test Systems Over 9000 Dealership Locations 46 Vehicle Manufacturing Plants 5 Continents 32 Languages 65 Vehicle Lines >8 Million Vehicles Tested/Year

5. History ECM Aftermarket Tool Manufacturers OEMTool Engineering • Clear Codes, Read Codes, Read Data • Communication Setup You must supplythem the “data” ETI

6. History ECM Aftermarket Tool Manufacturers OEMTool Engineering • Code List • Data Stream • Communications Info No Problem! Information Needed By Tech ETI

7. History ECM Gateway BCM Aftermarket Tool Manufacturers • Code List • Data Stream • Communications Info • Buss ECU’s are on • Special procedures • Reprogramming • Learn and Setup procedures • Service Information Data OEMTool Engineering ??? ? • Output Control Data • Data Sharing Information • ECU selection • Special security interfaces • Cross-ECU testing You must supplythem the “all the data” Information Needed By Tech • VIN • Diagrams • Lots of “questions” about vehicle (ie Heated Seats? Dinglehopper position?) ETI

8. History • The number of ECU’s has risen greatly (from 1 to over 100) • The electrical architecture has become very complex (from a single line to many lines on many gateways to many ECUs). • The amount of data each ECU can access is much greater (from 10 to over 1000) • The number of functions that must be performed to diagnose a vehicle has greatly increased (from 3-5 to hundreds)

9. Diagnostic Data Simple data was stored in a simple format YearMakeModel All information needed to identify the correct set of information for a vehicle could be derived from the VIN or from asking the repairman ECU Data Stream DTCs Comm Info

10. Diagnostic Data • The huge increase in complexity of the vehicle caused the OEMs to store their information in ever more complex ways in order to retain the ability to handle such large volumes of complex information • ECU information is stored in a “virtual” ECU shared by many vehicles with only some differences • Vehicle information is stored in a “virtual” vehicle shared by many physical vehicles with only some differences • These differences are controlled by rules.

11. Diagnostic Data YearMakeModel Engine SizeEngine Family Part Number PCM PCM1 Data Stream Data Stream Rules DTCs DTC Rules • Rule based data relationships are complex • Information needed to resolve the rules is difficult or impossible for a repairman to answer • OEM tool strategies used to resolve the rules are not always documented Comm Info Comm Info Rules PCM2 Data Stream Data Stream Rules DTCs DTC Rules Comm Info Comm Info Rules • In addition to the diagram, several other items can be rule controlled • Output controls, their pre-conditions, run conditions, and final reset functions • Test menu and sub menus • Configuration/Setup data PCM ‘N’ Data Stream Data Stream Rules DTCs DTC Rules Comm Info Comm Info Rules

12. Diagnostic Data • There are other systems that must also be used which have a host of input variables required in order to accurately resolve their rules: • Security Systems • As Built/As Configured systems • ECU Reprogramming Systems • Information Systems

13. Possible Solutions ECU Programming Security Systems As Built/As Configured Information System Standardized Ruie Input Shop Tool Standardized Build Interface Standardized Data Interface Vehicle Build System ECU Data Standardized VCI Interface (J2534/J22900) VCI Device

14. Challenges OEM Scan Tool Data • Different OEM’s store their information in different tool architectures • Putting the data into a standard flexible enough to hold any kind of OEM data for any kind of ECU is very challenging (and expensive) • This data format is not useful to the OEM (beyond their current formats) so the charge would likely be passed through to the aftermarket OEM Build Interface • Different OEM’s store their information in different formats OEM Rule Interface • Aligning all systems with the exact same input (ie “Year” is different than “MY”)

15. Thank You!