IAV PrimeroFault Simulation for Lambda Probes

What we develop moves youIAV – Your Partner for AutomotiveEngineering

Our engineering is at the heart of vehiclesacross the globe. As one of the leadingdevelopment partners to the automotiveindustry, IAV offers more than 30 years ofexperience and a range of skills second to none. With our expertise in the entirevehicle, and the passion to match, weprovide technically perfected solutions that balance both rational and emotional

Contact:

Are you interested in IAV Primeroor have any questions about theproduct? Simply get in touch withus, IAV’s experts will be pleased toadvise you.

iav-primero@iav.de+49 5371 80-53054

aspects. Employing 6,000 members of staffand first-class facilities, we assist manufac-turers and suppliers in carrying out theirprojects wherever they are in the world –from concept to start of production: Yourgoals are our mission.

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Contents

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01

5

Applications 4

How IAV Primero Works 5

Signal Curves and Fault Patterns 6

User Interface 7

Product Variants 8

Accessories 8

Services 9

Technical Parameters 10

4

L ambda probe on-board diagnostics(OBD) must be in a position to identifyaging effects on the lambda probe

well before it becomes unable to deliver thesignals needed for emission-relatedfunctions in the vehicle (e.g. mixture control,catalyst diagnosis).

IAV Primero makes it easy for developers tomanipulate the complex processing oflambda probe signals. It is capable ofproviding the engine control system’s OBDalgorithms with an lambda probe signalmodified on the basis of freely configurable

fault patterns. Here, the lambda probe’s signalpath is manipulated at vehicle level withoutthe need for any intervention in engine controlfunctions. The benefit is obvious: The efficacyof on-board diagnosis can be verified in itsunchanged volume production state anddemonstrated within vehicle homologation.

IAV Primero assists engineers throughout the OBD development process:• Algorithm development• Calibration• Vehicle homologation (OBD demonstration)

Simplifying development work saves timeand money: • Minimized use of reference sensors

(no retooling work involved anymore).• Complex faults that cannot be repro-

duced with reference sensors are alsoeasy to demonstrate.

• Selected fault patterns and their param-eters are easily saved, providing repro-ducibility and reusability.

ApplicationsLambda probes at the focus of exhaust emission legislation

Benefits at a glance:

• Support of a large number of lambda probes

• Large number of user-configurable fault patterns

• Scalable to the needs of vehicle projects

• Configurable for OBD demonstrations withinvehicle homologation

• Compact and robust design for in-vehicle use

• Customized upgrades possible

5

How IAV Primero WorksThird-generation fault simulation

V ersatile and flexible – IAV Primeromakes the redundancy easy tointegrate into the signal path between

lambda probe and engine managementsystem through the universal cable harnessin any vehicle environment. An IAV Primerocan be used for operating one linear sensorand binary sensor each simultaneously.

The unit is conveniently configured andcontrolled via the user interface from alaptop connected to IAV Primero by USB.The CAN interface provided permitsseamless integration of the data generatedby IAV Primero into the existing calibrationenvironment (for example, ETAS INCA).

IAV Primero is fully backward compatible withall sensor models and control units that haveso far been supported by previous Lambda-FST generations.

Features at a glance

• Detection of sensor operability• Extended binary sensor functions• Balancing resistor compensation• Scalable number of sensors and range of

functions• Simplified operating concept• Integrated configuration editor• Capability of updating firmware via the

user interface

Compatibility – control units

• Bosch with CJ-125, CJ-135• Continental with ATIC-42, ATIC-142

Compatibility – lambda probes

• Bosch LSU 4.2, LSU 4.9, LSUadv, LSU 5.1• Bosch LSF 4.2, LSF Xfour• NTK ZFAS-U2• NTK OZAS-S1, OZAS-S2

Basic principle underlying lambda probe fault simulation

Lambda probe(binary/linear)

Laptop via USB, CAN

Probe signal Engine management system

Simulated fault

011010100011010110111011010011010010100101010010100101110111011010100100101011011101010011010011101001010100110010111001110110101000110101101110010011010010100101010011

IAV Primero makes it easy for developers to manipulate the complex processing of lambda probe signals. It is capable of providing theengine control system’s OBD algorithms with an lambda probe signal modified on the basis of freely configurable fault patterns. Here,the lambda probe’s signal path is manipulated at vehicle level without the need for any intervention in engine control functions.

Further fault patterns

• Heater faults• Cable faults (short circuits, breaks, transfer and series

resistances)• Characteristic curve trimming• Conditioning• Gain• Limitation• Manipulation of internal resistances of binary sensors

Further functions

Sensor operability:IAV Primero comes with a function that provides flexibility inconfiguring sensor operability detection.

Further fault patterns and functions on request

Low pass

Offset

Low passSymmetric

Signal Curves and Fault PatternsWide range of manipulation options

6

Delay

DelaySymmetric (Maintaintransition)

DelaySymmetric (Abrupttransition)

DelayAsymmetric(Maintaintransition)

DelayAsymmetric(Abrupttransition)

DelayAsymmetric(Soft transition)

Original signal Manipulated signal

Low passAsymmetric (Rising edge)

Low passAsymmetric (Falling edge)

Offset

7

User modes at a glace

User InterfaceFlexibility and intuitive operation for every user

The graphic user interface makes IAV Primero easy and particularly convenient to use. The advantage lies in the ease of calibration andprecise adaptation for specific vehicle projects. Eight lambda probes can be controlled simultaneously through the graphic user interface.Providing three user modes, the operating software offers the right interface for every user.

Expert mode The expert mode provides full access to all of IAV Primero’s functions and administration of theother user modes.

Custom mode The custom mode permits access to predefined fault patterns with online adaptation of theparameters needed during the OBD development process.

Demonstration mode The demonstration mode is used for OBD demonstrations at the authorities.

Straightforward and intuitive – IAV Primero’s user interface

8

Basic Unit Extension CJ-135 Extension ATIC-142 Extension single-cell probe

Linear sensors

LSU 4.9 CJ-125 LSU 4.9 CJ-135 LSU 4.9 ATIC-142 LSU 5.1 CJ-135LSU adv ATIC-42 LSU adv LSU advNTK ZFAS-U2 NTK ZFAS-U2 NTK ZFAS-U2

Binary sensors

LSF 4.2 Analog – LSF 4.2 ATIC-142 –LSF Xfour Interface LSF XfourNTK OZAS-S1 NTK OZAS-S1NTK OZAS-S2 NTK OZAS-S2

Product VariantsConfiguration levels can be combined and matched to requirements

AccessoriesEasy integration into any vehicle project

Product variants

Cable and adapter

USB cable USB cable for connecting IAV Primero to user PC.IAV Primero comes complete with this connection cable.Length: 3,000 mm.

Universal adapter 19-pin measurement adapter cable assembly with banana plugs foruniversal connection of IAV Primero to supply voltage, engine controlunit and lambda probes. IAV Primero comes complete with this adapter.Length: 750 mm.

IAV Primero comes in a variety of configurations – tailored to the latest developments taking place at the manufacturers of lambda probesand their control systems. Proceeding from the basic unit, IAV Primero can be upgraded with various extensions as an easy way of adaptingthe development tool to the particular application in hand. The basic unit can be combined in any way with one or more extensions to covera wide range of control units and lambda probes. The extensions are upgrades for the basic unit.

9

ServicesFull support from day one

Support service

Ad-hoc device replacement service (subject to device availability from IAV)

Annual function check with report

Annual calibration with report

Updates and upgrades of device software

Individually tailored services provide first-class, all-encompassing customer support for IAV Primero throughout the product’s life cycle.Available for use on an optional basis, these services can be matched to the customer’s specific needs.

10

Technical ParametersIAV Primero

Weights and dimensions

Weight approx. 2.8 kg

Enclosure dimensions without measurement adapter 121 x 105 x 290 mm

Protection class IP 30

Maximum cable length (all connection cables) 3 m

Ambient conditions

Operating voltage DC 10.5 V min

Typically 13.8 V

17.5 V max.

Power consumption Typically 1.7 A

10 A max.

Ambient temperature during operation –10 °C min.

+40 °C max.

Relative air humidity 80% max.

Signal functional ranges (Wider functional ranges may be given depending on specific application)

Binary sensors Linear sensors

Internal resistance 100 ohms min. –

10,000 ohms max. –

Accuracy –3 mV min. –20 μA

+3 mV max. +20 μA

Resolution 1 mV 1 μA

Resistance decades

Resistance decade in the signal path 1 ohm min.

262,143 ohms max.

Continuous rating for resistance decade in signal path 75 mW

Resistance decade in heater path 1 ohm min.

127 ohms max.

Continuous rating for resistance decade in heater path 6 W

IAV GmbHCarnotstrasse 110587 BerlinGERMANY

Phone +49 30 3997-80Fax +49 30 3997-89790

www.iav.com