Faster and Better Development Result

From developers for developers: IAV Xingu for smart, scalable dataset management and IAV Primero for simulating lambda probe errors

From developers for developers: IAV products make work easier because they result from practical applications and are always state of the art. For instance, IAV Xingu for smart, scalable dataset management and IAV Primero for simulating lambda probe errors. IAV presented both products at the Testing Expo trade show (June 5 to 7) in Stuttgart.

Between 30,000 and 50,000 parameters have to be calibrated in an engine control unit. In transmissions the number is even higher: between 80,000 and 100,000. This makes it all the more important to have scalable, intelligent dataset and variant management, as with the tool IAV Xingu. IAV’s development engineers have been using it internally since 2006 and it was launched as a product on the market in 2008. The tool has been undergoing constant development since then. IAV Xingu makes it possible to define responsibilities (who is responsible for which parameters?). It stops any overwriting of parameter values by mistake. It keeps records (who changed which value when?) and manages the different variants with their history in a tree structure (which vehicle was configured when and how?).

IAV Xingu lets calibrators compare their work with the calibration guidelines, detect correlations and recognize possible conflicts with current legislation with regard to OBD, for example. Automatic calibration of derivatives is also possible, starting with a master calibration. “If the differences to the master calibration have been saved, then country-specific configurations can be generated just by pressing a button”, reports Veit Stobbe, specialist for dataset management and software architecture at IAV. “Feature calibration is another real USP. While performance and emissions are stipulated in the master dataset, adding other features such as drivability is as easy as picking items off a shelf.”

IAV Xingu: first choice at Deutz AG

IAV Xingu has been used at Deutz AG since 2010. In 2017, the company produced more than 160,000 diesel engines with power outputs between 19 and 500 kilowatts, down to batch sizes of just 1. “Our products are often highly customized, for example in terms of output or mechanical connections”, says Andreas Wehrmann, team leader for diagnostic tools and dataset management at Deutz. “Every variant has to be calibrated individually with up to 40,000 parameters, including around ten percent that are completely new for every customer.” This demands a sophisticated dataset management system, making IAV Xingu the first choice for management of the seven terabyte dataset database. The tree structure simplifies storage of the datasets with easy reconfiguration by Drag & Drop. For example, datasets can be separated according to output variant instead of exhaust standards.

Deutz has worked with IAV to optimize the tool, with new features being integrated in the current and coming year. “The IAV tool makes us swift and agile”, says Wehrmann. This can also be said for other customers. IAV helps to implement processes and datasets, provides assistance while setting up IAV Xingu and offers the support of its comprehensive knowhow that covers all aspects of dataset management.

Freely configurable lambda probe error patterns with IAV Primero

On-board diagnosis of the lambda probe has to recognize ageing effects early on before the probe is no longer able to supply the necessary signals for exhaust-relevant functions in the vehicle (such as mixture control or catalyst diagnosis).

IAV Primero checks whether this really works as it should. The tool makes it easy for developers to manipulate the complex processing of the lambda probe signals, simulating freely configurable error patterns for the engine control unit. Manipulation takes place on the vehicle level without any intervention in the ECU’s functions. It is thus possible to verify the efficacy of on-board diagnosis in unchanged production state, with demonstrations in the context of vehicle homologation procedures. IAV Primero drastically reduces workload and costs for OBD algorithm development and calibration. “The tool acts between the lambda probes and the engine control unit", explains Andreas Storbeck who developed Primero. “It simulates almost any errors. Engineers no longer need to fit faulty probes in the exhaust aftertreatment system to check the diagnosis system.” IAV Primero now performs this task by changing the signals as stipulated by the developers. It simulates all “six patterns”, i.e. the error patterns defined by the California Air Resources Board (CARB). IAV Primero also replicates electrical (OBD I) and customized errors.

“With IAV Primero it is possible to simulate all probe errors at all currently used combinations of ECU and lambda probes that have to be considered during the OBD development process”, says Gunnar Splisteser from OBD development at Volkswagen. “It is a tool that is known to the authorities and is suitable for OBD demonstration purposes during the homologation process. It works reliably and can be used with little workload both in the vehicle and also at the engine test bench.“

Third generation supports more probes and ECUs

As with its predecessor Lambda-FST, the IAV Primero tool is used for the provision and validation of new special ECU combinations in direct consultation with the customer, such as Volkswagen. “Here the approach has always entailed smooth, professional sharing”, says Splisteser. “Requests, suggestions or possible improvements are taken up and discussed with constructive interest, and then implemented as quickly as possible.”

IAV has meanwhile presented the third generation of the proven tool. It supports new probes such as Bosch LSU 5.2, NTK ZFAS-U3 and OZAS-S4 on established ECUs by Bosch or Continental, as well as new ECU/probe combinations, including the ECU families 10JA and 11GV by Magneti Marelli in combination with linear and binary sensors. IAV Primero can be integrated in the calibration environment with the CAN bus so that measured values can be compared and recorded before and after being manipulated. It also has a system configuration editor for simply adjusting the tool to vehicle-specific circumstances. Furthermore, firmware updates can be implemented by the user to make it easier to stay completely up to date.

“In contrast to other tools, IAV Primero is suitable for probe/ECU combinations of different makes”, says Storbeck. “The number of compatible sensors and ECUs will continue to grow in future. For example, we also plan to support the successor of the Bosch probe driver module CJ135, as well as derivatives by Delphi. The same can also be said for new linear and binary sensors by Denso.”

IAV Xingu

Dataset management system – previously called IAV CalGuide

  • Variant matrix management
  • Master / n-derivative level calibration
  • Feature calibration
  • Project scalability
    >2500 variants per project
    >250 datasets per variant
    >90,000 parameters per dataset
  • Traceability
  • Stable and robust

IAV Primero

Error simulation for lambda probes

    Error categories:

  • CARB Six Patterns (sym. / asymmetric transition, delay)
  • Offset and amplification errors
  • Electrical errors (e.g. short circuits, cable ruptures, series and contact resistance, inner resistance of binary probes)
  • User-defined error patterns

    Compatible engine control units:

  • Continental ATIC-42, ATIC-142
  • Bosch CJ-125, CJ-135
  • Magneti Marelli 10JA, 11GV
  • Bosch CJ-135 successor – in preparation
  • Delphi – in preparation

    Compatible probes:

  • Bosch linear: LSU4.9, LSU5.1, LSU5.2, LSUadv
  • Bosch binary: LSF4.2, LSFxFour
  • NTK linear: ZFAS-U2, ZFAS-U3
  • NTK binary: OZAS-S2, OZAS-S4
  • Denso – in preparation

    Service (optional):

  • Tools for hire
  • Set-up service
  • Support agreement
  • Annual function test
  • Annual alignment