Manufacturing of a motor vehicle and control unit

Abstract

A method for manufacturing a motor vehicle (105) comprises steps of determining an identification of the motor vehicle (105); installing a control unit (110) in the motor vehicle (105); connecting the control unit (110) to a device external to the motor vehicle (105); reading out a parts list from the control unit (110), wherein the parts list specifies components comprised by the installed control unit (110); and storing the parts list and the identification in the external device.

Description

[0001] -3222 PIF

[0002] 1

[0003] Manufacture of a motor vehicle

[0004] The present invention relates to the manufacture of a motor vehicle. In particular, the invention relates to the manufacture of a motor vehicle with a control unit.

[0005] A motor vehicle comprises one or more electronic control units (ECUs), each capable of controlling predetermined functions on board the vehicle. Should one of these ECUs fail or otherwise become unavailable, the vehicle's functionality may be substantially impaired. In the worst-case scenario, the vehicle may no longer be roadworthy or drivable.

[0006] The control unit comprises a number of components, all of which must be available to manufacture the control unit. If the supply chain for these components is disrupted, for example due to transportation difficulties, a natural disaster, or because the component is no longer manufactured, the production of the control unit can be jeopardized. Consequently, the production of the vehicle itself can also be jeopardized.

[0007] During vehicle production, it is not always known exactly which components are included in the electronic control units (ECUs) to be installed in the vehicle. To obtain this information, a manufacturer's production or procurement system for the ECUs can be linked to the manufacturer's vehicle management system. However, such a linkage is complex and prone to errors. Furthermore, it can be difficult to ensure that a list of components planned for installation in an ECU matches a list of components that were actually installed. This can be particularly true if the ECU includes a component sourced from another manufacturer. -3222 PIF

[0008] 2

[0009] One of the problems underlying the present invention is to provide an improved technology for managing components installed in control units of motor vehicles. The invention solves this problem by means of the subject matter of the independent claims. Dependent claims describe preferred embodiments.

[0010] According to a first aspect of the present invention, a method for manufacturing a motor vehicle comprises steps of determining an identification of the motor vehicle; installing a control unit in the motor vehicle; connecting the control unit to a device external to the motor vehicle; reading a parts list from the control unit, wherein the parts list specifies components that are included in the installed control unit; and storing the parts list and the identification in the external device.

[0011] The invention can be particularly advantageous in connection with the series production of motor vehicles. Components installed in control units (ECUs) in manufactured motor vehicles can be centrally stored and managed by the vehicle manufacturer. The production or planning of motor vehicle production can then be based on the collected data. The collected data can also open up further possibilities, such as the cost-effective central procurement of components comprised of different ECUs, or the ability to track the pricing of an ECU based on the parts list.

[0012] The method can be based on a known technique for storing the parts list in the control unit. Such a technique is proposed, for example, in EP 3 839 724 A1.

[0013] It is particularly preferred that the parts list be read via an electronic interface of the control unit. This interface can be the 3222 PIF.

[0014] 3

[0015] The interface can be wired or wireless. Examples of wireless interfaces include WLAN, cellular networks, NFC, or proprietary radio interfaces. The control unit's interface is preferably connected to a vehicle communication system, which itself includes an interface. This interface can also be wired or wireless. The parts list can be read via the vehicle's interface, for example, during a functional test. The functional test can be scheduled at a predetermined point in the vehicle manufacturing process. The functional test can also be performed before the vehicle is completed, allowing for corrections if an error is detected during the test.

[0016] The components listed in the parts list may include, in particular, electronic components that are part of the control unit. These electronic components may be passive or active. Specifically, the components may include semiconductors or integrated circuits. Examples of semiconductors include power transistors, which may be used, in particular, to control the drive motor in an electrically powered vehicle; examples of integrated circuits include microprocessors or microcontrollers, which may be used to control a function in the vehicle.

[0017] In one embodiment of the invention, the control unit comprises at least one printed circuit board (PCB) populated with electronic components. The parts list can specify the components mounted on the PCB. At the time of PCB assembly, the components to be used can be known with a high degree of reliability. The parts list can be generated shortly before PCB assembly. If the PCB includes a memory component, the parts list can be stored in the memory before or after the memory component is mounted on the PCB. The memory component can also be part of a microcontroller. If the control unit comprises multiple PCBs, multiple parts lists can be generated.

[0018] 4

[0019] Storage areas should be provided, each containing a parts list of components installed on the respective circuit board and / or another circuit board of the control unit. Separate parts lists can be stored for different functional groups of the control unit, for example, different circuit boards.

[0020] The parts list may include a reference to a version of the control unit. This reference may be designed in such a way that the parts list is distinguishable from a parts list of an earlier version of the control unit. The reference may correspond to a marking on the control unit or one of its components. For example, a version number may be printed on a circuit board of the control unit, and the parts list may include a corresponding version reference.

[0021] In another embodiment, it is possible to record information about additional components in the parts list. Such components can include, in particular, structural parts such as a housing, a heat sink, a cable, a connector, or a retaining element. Furthermore, additional information can be stored, for example, a unique identifier for the control unit, a manufacturing date, or a source for a component.

[0022] The parts list can include a unique identifier for each component and the number of units installed in the control unit. The identifier is preferably in a format that allows the component to be sourced from different suppliers. For example, for a resistor, the list can specify its resistance value, current rating, tolerance, and package type. In a less preferred embodiment, an internal manufacturer's designation can be used. In this case, it is preferred that a reference to the manufacturer be included to allow for subsequent determination of the component's properties.-3222 PIF

[0023] 5

[0024] Parts lists for a large number of manufactured vehicles can be collected. Should it later turn out that a component used in numerous control units is defective, the collected data can be used to determine which control units contain such a component and which vehicles have these control units. A service action, such as a software update or a recall, can then be planned accordingly.

[0025] The parts list is preferably read during the manufacturing, testing, or transport of the vehicle. Generally, it is preferred that the parts list be read before the vehicle is handed over to a user. For example, the parts list can be read at a dealership or transport company. This ensures that the information about the components used remains with the vehicle manufacturer.

[0026] The parts list can be accessed at any time, optionally even after it has been handed over to the user. However, the parts list can be protected so that it cannot be read by just anyone. For example, downloading it can be cryptographically protected. The content of the parts list can be cryptographically encrypted.

[0027] The availability of a component listed on the parts list can be determined; based on this component's availability, the availability of the control unit can then be determined. This allows for early identification of potential supply difficulties for a control unit if the availability of a component included in the control unit decreases. Based on control unit inventory and any commitments from the control unit manufacturer, it is then possible to estimate how many vehicles can be produced without changes before a required control unit becomes unavailable. -3222 PIF

[0028] 6

[0029] The production of motor vehicles can be controlled depending on the availability of the control unit. For example, attempts can be made to procure an alternative control unit in a timely manner, or efforts can be made to prioritize the production of motor vehicles that do not require the control unit.

[0030] According to a further aspect of the present invention, a method for manufacturing a control unit comprises steps of determining a parts list specifying components included in the control unit; installing the specified components; and storing the parts list in the control unit.

[0031] It is preferred that the parts list is stored in the control unit only after the components included in the parts list have been assembled. It is further preferred that the parts list be stored in the control unit as soon as possible after the components have been assembled. This improves the degree of consistency between the parts list and a list of the components actually installed in the control unit.

[0032] In a further embodiment of the invention, the parts list for a component can include a reference to an alternatively usable replacement type. Should the use of the replacement type require that another component of the control unit also be modified or replaced, a corresponding note can be included in the parts list. In another embodiment, such a note can be omitted, particularly if only certain components, the procurement of which may be problematic, are included in the parts list. Other components that are usually easy to procure, for example, standard resistors, standard capacitors, or standard inductors, can be excluded from the parts list in one embodiment.-3222 PIF

[0033] 7

[0034] According to yet another aspect of the present invention, a control unit comprises a memory and an interface. The memory is writable only once and contains a parts list specifying the components included in the control unit. Preferably, the parts list for each component also includes the number of units installed in the control unit (or in a component covered by the parts list). The parts list can be read from the memory via the interface.

[0035] The memory of the control unit can, in particular, include an OTPROM (One Time Programmable Read-Only Memory).

[0036] The control unit may include a processing unit configured to partially or completely execute a procedure described herein. For this purpose, the processing unit may be electronic and may include, for example, an integrated circuit, a programmable logic device, or a programmable microcomputer.

[0037] A method described herein may be implemented in the form of a configuration or as a computer program product with program code means for the processing device. The configuration or the computer program product may be stored on a computer-readable data carrier. Features or advantages of the method may be transferred to the device or vice versa.

[0038] According to yet another aspect of the present invention, a motor vehicle comprises a control unit as described herein. The motor vehicle can, in particular, be a passenger car or a motorcycle.

[0039] The invention will now be described in more detail with reference to the attached drawings, in which:-3222 PIF

[0040] 8

[0041] Figure 1 shows a production line for motor vehicles;

[0042] Figure 2 shows a flowchart of a first procedure;

[0043] Figure 3 shows a flowchart of a second procedure;

[0044] Figure 4 shows a flowchart of a third procedure; and

[0045] Figure 5 shows a flowchart of a fourth procedure

[0046] illustrated.

[0047] Figure 1 schematically shows an exemplary production line 100 for motor vehicles 105. Partially completed motor vehicles 105 move along the production line 100 from left to right, undergoing processing steps to complete the motor vehicles 105. A control unit 110 is required to manufacture a motor vehicle 105; its installation is indicated in the left area of ​​Figure 1.

[0048] In a later assembly step, shown in the center of Figure 1, the motor vehicle 105 is connected to an external device 115. The device 115 preferably comprises a processing unit 120 and a data storage device 125. The motor vehicle 105 includes an interface 130 configured to connect to the external device 115. The interface 130 can be connected to a data bus 135 on board the motor vehicle 105. The control unit 110 can be connected to the data bus 135 or directly to the interface 130 of the motor vehicle 105. For this connection, the control unit 110 preferably includes an interface 140. The interface can be wired or wireless. A processing unit 145 and a storage device 150 are also preferably provided.Information stored in memory 150 of control unit 110 can be transmitted via interface 140 to external device 115 and stored in data storage 125.-3222 PIF.

[0049] 9

[0050] It is proposed that a parts list containing a list of components included in the control unit 110 be stored in memory 150. This parts list can be read and saved to the external device 115 during the production of the motor vehicle 105. The production of motor vehicles 105 can then be controlled based on the data collected in this way.

[0051] The control unit 110 can comprise a variety of components, at least some of which are electrical or electronic components. Examples of electronic components include resistors, capacitors, inductors, diodes, transistors or other semiconductors, as well as integrated circuits. An integrated circuit can, in particular, comprise a microprocessor, a microcontroller, or a peripheral device. Other or additional electronic components are also possible.

[0052] A component is typically specified by its functional specifications. For example, an electrical resistor might be characterized by its value, tolerance, current rating, and / or package type. Alternatively, a component might be identified by a manufacturer-specific designation. A manufacturer-specific designation is particularly common for integrated circuits. Optionally, a reference to a replacement component that can be used instead may be included. This could include the designation of a compatible component from another manufacturer.

[0053] The memory 150 preferably comprises a read-only memory containing no moving parts. In particular, a semiconductor memory can be used. In one embodiment, the memory 150 is configured to be written to only once. For this purpose, all memory cells (bits) can initially have a uniform value, which can be changed to a different value once. A once-written bit pattern representing a predetermined piece of information,-3222 PIF

[0054] 10

[0055] Therefore, it cannot be overwritten by any other information.

[0056] Figure 2 shows a flowchart of a first method 200 for manufacturing a control unit 110 described herein. In step 205, a list of components comprising the control unit 110 can be determined. The parts list can be exhaustive, including all components of the control unit 110. Alternatively, the parts list can be partial, listing, for example, only those components with a predetermined level of complexity. It can also include only those components for which future availability is considered uncertain. Generally, it is preferred that the parts list includes only electrical or electronic components. The control unit 110 can comprise a printed circuit board, and the parts list can include only components that are mounted and, in particular, soldered to the circuit board.The printed circuit board can be populated with components using a pick-and-place machine, which can then be soldered to the board. In one embodiment, the parts list is generated based on control information from the pick-and-place machine.

[0057] In step 210, the designations for the individual components can be adjusted. For example, a proprietary designation can be converted into a generic one. Optionally, a substitute type can be specified for a component. Further information, such as a supplier, can also be provided. The collected information can then be compiled into a parts list. The parts list is preferably created in a universal format that allows for easy evaluation by a variety of tools or computer programs. In one embodiment, the parts list comprises a table, which can be provided in CSV format.

[0058] In step 215, one or more circuit boards encompassed by the control unit 110 can be populated. The at least one-3222 PIF

[0059] 11

[0060] The printed circuit board can be assembled with other components, such as housing parts, connectors, cable harnesses, etc.

[0061] In step 220, the control unit 110 is functional to the point that its interface 140 allows write access to the memory 150. At this point, the parts list can be written to the memory 150. Optionally, this step is performed as part of a functional test, calibration, or quality assurance of the control unit 110.

[0062] It should be noted that in another embodiment, the parts list can also be written to memory 150 at an earlier time. This can be done in particular before memory 150 is installed in control unit 110.

[0063] In step 225, the finished control unit 110 can be provided to be installed in a motor vehicle 105.

[0064] Figure 3 shows a schematic flowchart of a second method 300 for manufacturing a motor vehicle 105. In step 305, the motor vehicle 105 can be identified. In one embodiment, only a type or model of the motor vehicle 105 can be recorded; however, preferably an individual identifier of the motor vehicle 105 is determined, for example, a VIN (Vehicle Identification Number).

[0065] In step 310, the control unit 110 is installed on the motor vehicle 105. For this purpose, the control unit 110 is usually attached to the vehicle 105 and electrically connected to it.

[0066] In step 315, the parts list is read from memory 150 of control unit 110 and saved in external device 115. For this purpose, external device 115 can be directly connected to interface 140 des-3222 PIF.

[0067] 12

[0068] The external device 115 is connected to the control unit 110. However, it is preferred that the external device 115 is connected to the interface 130 of the motor vehicle 105, via which communication with the control unit 110 is ultimately possible.

[0069] It should be noted that the parts list is preferably read only after the control unit 110 has been installed in the vehicle 105. However, it is also conceivable to read the parts list from the memory 150 of the control unit 110 before it is installed in the vehicle 105. In this case, it is preferable that the reading takes place as close as possible to the installation of the control unit 110.

[0070] The external facility 115 can collect and store parts lists for a large number of manufactured motor vehicles 105. The collected data can be used to control the production of motor vehicles in a step 320.

[0071] Figure 4 shows a flowchart of a third procedure 400 for responding to a potential component defect in already installed control units 110. In step 405, a problematic component is identified. A component can be identified as problematic if a serial defect is present, if it has proven unreliable, or if a failure is to be expected. Other reasons are also possible.

[0072] In step 410, based on information stored in data storage 125, control units 110 in which the potentially problematic component is installed can be identified. In step 415, motor vehicles 105 in which these control units 110 are installed can be identified. Preferably, the data stored in data storage 125 allows each motor vehicle 105 in which a potentially problematic component is installed to be individually identified.-3222 PIF

[0073] 13

[0074] In step 420, a service action can be determined. This service action can include, for example, replacing a control unit 110, updating software, repairing individual control units 110, or another measure. Furthermore, the production of motor vehicles 105 can be controlled such that control units 110 containing the problematic components are no longer used in the manufacture of motor vehicles 105.

[0075] Figure 5 shows a flowchart of a fourth method 500 for the predictive control of the production of motor vehicles 105. In step 505, a potential disruption of a supply chain leading to the motor vehicle 105 can be determined. For example, if it becomes known that an earthquake has occurred in a region where many manufacturers of electronic components are located, a potential disruption of the supply chain can be assumed.

[0076] In step 510, components affected by the malfunction can be identified. In the example given, the entire range of components from manufacturers located in the region can be identified as affected. A component can only be considered potentially affected if it is used in a control unit 110 that is to be installed in one of the motor vehicles 105.

[0077] Optionally, in step 515, it can be determined whether a comparison type is available for an affected component. If the comparison type also includes a component potentially affected by the supply chain disruption, an attempt can be made to determine a different comparison type. If a comparison type is found, the corresponding component can be considered unaffected.

[0078] In step 520, it can be determined which control units 110 may no longer be manufactured if the-3222 PIF

[0079] 14

[0080] a specific disruption in the supply chain lasts long enough. In particular, it can be determined how long the production of the control units 110 can be maintained during the disruption and how long the manufacture of motor vehicles 105 can continue with respect to the control units 110. For this purpose, information from a planning system, for example regarding orders for the production of motor vehicles 105, can be used.

[0081] In step 525, it can be determined which vehicle type 105 might be affected by a potential shortage of control units 110. In step 530, the production of vehicles 105 of the determined vehicle type can be controlled accordingly. In particular, an attempt can be made to produce only vehicles 105 that do not include a control unit 110 containing components that may be unavailable.-3222 PIF

[0082] 15

[0083] Reference sign

[0084] 100 production line

[0085] 105 motor vehicles

[0086] 110 Control unit

[0087] 115 external institution

[0088] 120 processing unit

[0089] 125 data storage

[0090] 130 Motor vehicle interface

[0091] 135 Data bus

[0092] 140 Control unit interface

[0093] 145 Processing unit

[0094] 150 storage

[0095] 200 first procedure

[0096] 205 Determine the parts list

[0097] 210 Adjust labels, determine parts list 215 Populate circuit boards, assemble control unit 220 Write parts list to memory

[0098] 225 Provide control unit

[0099] 300 second procedure

[0100] 305 Identify motor vehicle

[0101] Install 310 control unit

[0102] 315 Read and save parts list

[0103] 320 Control the manufacture of motor vehicles

[0104] 400 third procedure

[0105] 405 Determine problematic component

[0106] 410 control units with this component are identified

[0107] 415 Determine motor vehicles with this control unit 420 Determine service measure-3222 PIF

[0108] 16

[0109] 500 fourth procedure

[0110] 505 Determine potential supply chain disruption

[0111] 510 Determine the affected component

[0112] 515 Comparison type available?

[0113] 520 Determine the affected control unit

[0114] Determine the 525 affected vehicle types

[0115] 530 Control the manufacture of vehicles of the vehicle type

Claims

-3222 PIF 17 Claims 1. Method (300) for manufacturing a motor vehicle (105), wherein the method (300) comprises the following steps: Determine (305) an identification of the motor vehicle (105); Install (310) a control unit (110) in the motor vehicle (105); Connect (315) the control unit (110) to a device external to the motor vehicle (105); Reading (315) a parts list from the control unit (110); wherein the parts list specifies components that are included in the installed control unit (110); and Saving (315) the parts list and identification in the external facility.

2. Method (300) according to claim 1, wherein the parts list is read via an electronic interface (140) of the control unit (110).

3. Method (300) according to claim 1 or 2, wherein the components comprise electronic components encompassed by the control unit (110).

4. Method (300) according to one of the preceding claims, wherein the parts list includes a reference to a version of the control unit (110) 5. Method (300) according to one of the preceding claims, wherein the parts list for a component includes a unique identification and a number of copies installed in the control unit (110).

6. Method (300) according to any one of the preceding claims, wherein parts lists of a plurality of manufactured motor vehicles (105) are collected.-3222 PIF 18 7. Method (300) according to one of the preceding claims, wherein the parts list is read out before the motor vehicle is handed over to a user.

8. Method (300) according to any of the preceding claims, wherein the availability of a component specified on the parts list is determined; and the availability of the control unit (110) is determined on the basis of the availability of the component.

9. Method (300) according to claim 8, wherein the manufacture of motor vehicles (105) is controlled depending on the availability of the control unit (110).

10. Method (200) for manufacturing a control unit (110), the method comprising the following steps: Determine (210) a parts list specifying components included by the control unit (110); Install (215) the specified components; and Saving (220) the parts list in the control unit (110).

11. Method (200) according to claim 10, wherein the parts list is stored in the control unit (110) only after the components included in the parts list have been assembled.

12. Method (200) according to claim 10 or 11, wherein the parts list for a component includes a reference to an alternatively usable replacement type.

13. Control unit (110) comprising a memory (150) and an interface (140); wherein the memory (150) includes a parts list specifying components included in the control unit (110); and wherein the parts list is readable via the interface.-3222 PIF 19 14. Motor vehicle (105) comprising a control unit (110) according to claim 13.

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