ECU-Based Vehicle Inspection for Accurate Current Testing

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Solution Overview

Problem

Manual electronic inspection of electric components in vehicle manufacturing plants is prone to measurement errors and human errors due to the use of aging current meters and varying inspection methods, leading to inaccurate and unreliable results, especially when multiple items are inspected simultaneously within a limited process cycle time.

Innovation Solution

An automated vehicle inspection system utilizing a diagnostic terminal connected to the engine control unit (ECU) through a watertight booth process, which sequentially operates individual electric components, measures their currents, and compares them with reference ranges to determine normal operation, using wireless communication and position recognition to ensure accurate and reliable inspections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple electric components are simultaneously inspected by multiple operators using current meters, then the inspection can be completed within the process cycle time, but measurement errors and human errors occur due to aging equipment and operator variations

Engineering Contradiction:

Improveinspection speedVSAvoidcurrent measurement accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent replaces manual mechanical inspection methods with an automated diagnostic terminal that electronically communicates with the vehicle's ECU. The system automatically activates electric components and measures current through digital communication protocols, eliminating the need for physical current meters and manual operator intervention, thereby resolving measurement accuracy issues while maintaining inspection speed

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The diagnostic terminal performs self-diagnosis by automatically communicating with the vehicle's ECU to activate and test electric components without external manual operation. The system autonomously measures current values, compares them against stored reference ranges, and generates inspection results, eliminating human error and equipment aging issues

Inventive Principle:

Principle #25Self-service

2Adaptability or versatility

If manual inspection methods are used with multiple operators, then flexibility in handling different vehicle specifications is maintained, but inspection reliability deteriorates due to variations in operator skill and carelessness

Engineering Contradiction:

Improveinspection method flexibilityVSAvoidinspection result reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The system stores reference current ranges for different vehicle types and specifications in the diagnostic terminal's memory. The ECU transmits appropriate reference values based on vehicle identification, allowing the system to adapt to different vehicle configurations while maintaining consistent, reliable measurement criteria through automated parameter comparison rather than subjective operator judgment

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The diagnostic terminal receives real-time current measurement data from the ECU and automatically compares it against stored reference ranges. The system provides immediate feedback by determining whether each electric component operates normally or abnormally based on this comparison, eliminating the need for operator interpretation and ensuring consistent reliability across all inspections

Inventive Principle:

Principle #23Feedback

3Quantity of substance

If a limited number of current meters are used by multiple operators, then equipment cost is reduced, but current measurement value dispersion increases due to accumulated errors

Engineering Contradiction:

Improvenumber of current metersVSAvoidcurrent measurement consistency

Core Design Contradiction:

Quantity of substanceVSMeasurement precision

Solution Approach 1:

The diagnostic terminal serves as a universal inspection device that can test multiple different electric components across various vehicle specifications through a single unit. The system communicates with the vehicle's ECU to activate and measure different components as needed, eliminating the need for multiple specialized current meters while maintaining measurement consistency through digital measurement and automated comparison protocols

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11745813B2System and method for vehicle inspection

Publication Date: 2023.09.05 HYUNDAI MOTOR CO LTD

AI summary

An automated vehicle inspection system includes a diagnostic terminal mounted in a vehicle and connected to an engine control unit (ECU) of the vehicle, sequentially operating individual electric components through the ECU based on stored electric component inspection items while the vehicle passes through a watertight booth and receiving individual operating currents measured to determine whether the electric components normally operate, a transceiver connecting to the diagnostic terminal and a wireless diagnostic communication network through an antenna disposed in the watertight booth process line, and an inspector recognizing a vehicle ID of a vehicle that enters the watertight booth, transmitting inspection items according to a vehicle type and specification of the vehicle ID to the diagnostic terminal through the diagnostic communication network, and recognizing a vehicle ID of a vehicle that leaves the watertight booth to collect inspection results determined in the diagnostic terminal.