Controller Calibration Tuning for Sensitive Manufacturing Diagnostics
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Solution Overview
Problem
Current manufacturing diagnostics for vehicle components, such as steering systems, often fail to detect latent issues during testing, leading to potential quality problems and component scrapping, as they rely on calibration values similar to those used in commercial environments, which may not capture all issues effectively.
Innovation Solution
A method and system that adjust calibration values to increase diagnostic sensitivity during testing, allowing for the identification of potential issues by flashing modified calibration values to controllers, and adjusting them based on diagnostic flags, including selectively decreasing or increasing sensitivity to differentiate between false positives and actual issues, ultimately flashing production calibration values after successful testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If calibration values similar to commercial environment values are used during manufacturing testing, then the testing process is simple and fast, but latent issues are not detected effectively
Solution Approach 1:
The patent modifies calibration values from commercial environment values to testing environment values that are more sensitive to latent issues. This parameter change allows the diagnostic system to detect manufacturing defects that would otherwise be missed, directly resolving the contradiction between detection sensitivity and testing simplicity.
2Reliability
If diagnostic sensitivity is increased to detect latent issues, then manufacturing quality improves, but false positive responses increase
Solution Approach 1:
The patent implements dynamic adjustment of calibration values based on diagnostic outcomes. When false positives are detected, the system adjusts the calibration values to reduce sensitivity for that specific component type, while maintaining high sensitivity for other components. This dynamic adaptation resolves the contradiction between detecting latent issues and minimizing false positives.
Solution Approach 2:
The system uses feedback from diagnostic test results to iteratively refine calibration values. By analyzing false positive patterns and adjusting calibration parameters accordingly, the system learns to distinguish between actual defects and false alarms, improving manufacturing quality while reducing false positive rates.
3Measurement precision
If modified calibration values are used during testing, then latent issues are detected, but additional testing iterations are required
Solution Approach 1:
The patent applies modified calibration values in a preliminary testing phase before final production testing. This preliminary action with enhanced sensitivity values allows detection of latent issues early, preventing the need for multiple re-testing iterations and reducing overall testing cycle time despite the initial sensitivity adjustment.
Data Source
AI summary
A method for identifying potential component manufacturing issues identifying a first set of calibration values corresponding to a first component and flashing a controller associated with the first component with the first set of calibration values. The method also includes performing at least one diagnostic test on the first component and, in response to receiving at least one diagnostic flag resulting from the at least one diagnostic test, determining whether the at least one diagnostic flag includes a false positive response. The method also includes, in response to a determination that the at least one diagnostic flag includes a false positive response, selectively adjusting at least one calibration value of the first set of calibration values and, in response to a determination that the at least one diagnostic flag does not include a false positive response, flashing the controller associated with the first component with a first set of production calibration values.