FEV ASM Box: Efficient verification of engine diagnostic functions

FEV offers first series product for manipulation of LSU 5.1 lambda sensors and simulation of complex injection system failures

OBD application, PVE and certification made easy: The FEV ASM Box achieves realistic failure patterns by manipulating the signal exchange between actuators or sensors and the ECU. Thus the correct function of the engine diagnostics can be verified (Image: FEV GmbH).

For the first time the ASM Box now contains a module for the manipulation of LSU 5.1 lambda sensors and simulates even complex failure patterns. Modules for further O2-sensor types will be available shortly (Image: FEV GmbH).

Aachen, 11 November 2014 – Compact, cost-efficient and versatile: With the Actuator Sensor Manipulation (ASM) Box, Aachen-based engineering service provider FEV offers a powerful tool for manipulation of the signal exchange between actuators and an engine control unit (ECU). The ASM Box allows the generation of realistic failure patterns required for OBD calibration and homologation. It now contains a module for the manipulation of LSU 5.1 lambda sensors and is the first commercially available system on the market.

"Our ASM Box makes the cost and time intensive usage of faulty hardware for failure generation unnecessary," explains Professor Stefan Pischinger, President and CEO of the FEV Group while commenting on the background of the development. "It simulates even complex failure patterns – for example, injection system behavior, for which we can vary duration, sequence and timing."
Complete parameterization of failure patterns is possible via any calibration tool such as INCA^®. In addition, the ASM Box offers a “government mode” that reduces the control of the manipulation to the scope required for U. S. homologation.

The correct function of engine diagnostics must be verified within the scope of vehicle certification,. FEV developed the ASM Box to quickly and cost-efficiently simulate the increasingly complex set of failure scenarios. It achieves realistic failure patterns by manipulating the signal exchange between actuators or sensors and the ECU.
"With a variety of interfaces and sensor connections we are capable of manipulating almost every signal – from exhaust gas recirculation to crankshaft signal, from injection parameters to NO_x or particle sensors," explains Rafael Dziadek, Product Manager at FEV.

Lambda manipulation for LSU 5.1 possible for the first time
As the first series system worldwide, the ASM Box enables manipulation of the O₂ signals of the lambda sensor. "The new sensor type LSU 5.1 requires a significantly more complex system than its predecessor to fulfil all of the vehicle homologation requirements," explains Dziadek.

The new and completely digital Bosch ASIC CJ135-Chip (ASIC) controls the pump current in the sensor via digital pulse width modulation (PWM) signals in the engine controls, in contrast to its analog predecessor, CJ125. The LSU 5.1 is a planar ZrO2 single cell limiting current sensor that has been developed by Bosch especially for use in the exhaust gas system of diesel combustion engines.

With the ASM Box, users can imprint various failure types on the sensor signals, including insufficient response behavior and implausible oxygen concentrations or limits. In addition, the system generates reproducible errors for ceramic temperature signals, heater duty cycles, the wiring, and all electrical failure patterns required by legislation.

Simulation of complex misfire
Even complex misfire and injection failures can now be simulated with the FEV ASM Box for up to five injections per work cycle. Apart from variations of the injection duration, injection and ignition timing migration can be represented as well. Complete ignition or injection failures can be generated randomly, in a regular sequence or continuously, and even single pilot injections can be blanked out or manipulated.

Interested parties can request further information about the FEV ASM Box directly from the FEV product management: Rafael Dziadek (Dziadek@fev.com)

About FEV
The FEV Group with headquarters in Aachen, Germany, is an internationally recognized development service provider for drive and vehicle technologies. The company offers its global transport industry customers a complete range of engineering services, providing support in the design, analysis and prototyping for powertrain and transmission development, as well as vehicle integration, calibration and homologation for advanced internal combustion gasoline-, diesel-, and alternative-fuelled powertrains. FEV's competencies also include design, development and prototyping of innovative vehicle concepts, powertrain electronic control systems and hybrid-electric engine concepts that address future emission and fuel economy standards. The Test Systems division is a global supplier of advanced test cell, instrumentation and test equipment. The FEV Group employs a staff of over 3,000 highly skilled specialists at advanced technical centres on three continents.