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17.06.2019

Review: DSA at Automotive Testing Expo 2019 – Diagnostics in the Digital Factory

Under the motto "Diagnostics in the Digital Factory", DSA presented new possibilities for a dynamic vehicle assembly and electronic commissioning at this year's Testing Expo 2019 in Stuttgart. In various demonstrations, the exhibition team showed the interested visitors how to achieve full control and more transparency in automotive production through the integration of connected vehicles, workers, machines and processes.

Diagnostics in the Digital Factory

At the fair, our booth visitors were able to test future technologies in the automotive industry by means of various live demos. They were presented innovative solutions for vehicle configuration and diagnostics that help automakers prepare for the digital revolution.

In one of the live demonstrations our guests learned that the use of augmented reality in vehicle production offers many advantages. While testing the DSA application for the Microsoft HoloLens, the visitors were guided through the commissioning process in the line by means of interactive 3D projections that informed them about parts to be picked.
The app not only leads to considerable time savings and improved documentation, but also enables digital processing of the results.
In addition to the solution for digitizing the worker, the visitors experienced how the DSA PRODIS system is able to connect with a variety of external device types, such as an electric screwdriver. M2M communication assists the worker during assembly, eliminates human error sources and reduces production times many times over.

Furthermore, our booth visitors were able to get an idea of the new features of the server backend PRODIS.PlantHUB. In addition to the diagnostic components, PRODIS.PlantHUB can now also connect and visualize external systems, such as robots, and monitor their condition. Moreover, external positioning systems can be integrated into the solution, so that it is possible to trigger test procedures without human interaction when a vehicle enters a defined area. Also, the exact position of the workers in the production line is no problem.

Our guests were also able to find out about our solution for testing high-voltage batteries. In combination with our Module Test Systems MTS, the DSA High Voltage Battery Tester (HVBT) is able to flash the control unit in the battery, to communicate with it and thus to activate the battery. By means of the control unit, complex measurements can be carried out within the battery, various measurement results of the battery management system (BMS) can be retrieved and charging and discharging processes can be initiated. Also, electrical high voltage tests (insulation tests) and non-electrical measurements, e.g. the leak test of the cooling circuits can be performed using the HVBT.

In addition, the trade fair visitors were able to inquire about the DSA diagnostic software stack (based on PRODIS.MCD and PRODIS.PDU) in different operating concepts. Depending on the particular use case and the performance of the vehicle’s on-board computer, the various aspects of a test client can be distributed to different components. For example, the All-in-One Diagnostics Tester, the DSA Multi-Function Tester MFT-3, integrates the user interface (HMI), process execution and diagnostic kernel as well as the vehicle interface in one device. While the Lean Diagnostics Edge (e.g the DSA WDI-2X) is connected to the component for sequence execution via WLAN and the execution of the test is performed on a corresponding hardware computer at the line or in the data center on a virtualized tester, the circulation tester Smart Diagnostics Edge (e.g. the DSA smartMDI) independently performs test procedures. In the Connected Vehicle, however, the vehicle’s on-board computer contains the VCI (On-Board Diagnostics Edge). Depending on the performance, the execution of diagnostic scopes on the on-board computer is also possible.

Last but not least, a live demo of our Connected Vehicle platform could not be missing. All data collected from the vehicle (CAN trace logs, vehicle condition, position, etc.) along with additional information from other sources (vehicle configuration, etc.) are documented and analyzed in the Connected Vehicle platform. Our guests found out that the system provides valuable insight through clustering and multivariate analysis, helping to understand vehicle performance. For example, possible patterns can be identified for preventive maintenance and root cause analysis. For OEMs, our portal and backend solution also provides the ability to define and execute software over-the-air updates and configuration changes to all ECUs in the vehicle, as well as to perform remote diagnostics.

Next year, we will once again present exciting topics and innovative new products at the Testing Expo—please reserve 16th to 18th June 2020!


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