SKF France TPMS-ECU TPMS ECU collects TPMS EWMs data, diagnose it to give tire pressure status to truck driver User Manual Mounting instructions of TPMS

SKF France TPMS ECU collects TPMS EWMs data, diagnose it to give tire pressure status to truck driver Mounting instructions of TPMS

Mounting instructions of TPMS

Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 1 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) TPMS Mounting Instructions For products 21851508 / 21780658 / 21780660 / 21780662 / 21923656 Document status: in work ( ) / under review () / released (X) / obsolete ( )
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 2 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) Table of contents ABBREVIATIONS .................................................................................. 3NAMING CONVENTIONS ......................................................................... 41REVISION HISTORY .................................................................. 52SCOPE ................................................................................... 63PRECONDITIONS ...................................................................... 74SYSTEM DESCRIPTION ............................................................... 84.1System goals ......................................................................... 84.2End customer benefits ............................................................. 94.3User profiles .......................................................................... 94.4System applications ................................................................ 94.4.1Driving situation ..................................................................................... 94.4.2Configuration by the end customer ......................................................... 104.4.3Configuration during truck production ..................................................... 104.4.4Single tire change on road ..................................................................... 104.4.5Maintenance, service by the workshop .................................................... 105TPMS MOUNTING INSTRUCTIONS .............................................. 125.1SW download ....................................................................... 125.2Mounting the TPM ECU .......................................................... 135.3Mounting the WMs ................................................................ 145.4Front and tag/pusher axle installation with single mounted wheel 165.4.1Counter weight .................................................................................... 165.4.2Protecting ring ..................................................................................... 175.4.3Light weight pusher axle (WTP-D245) ..................................................... 175.5Rear and tag axle double mounted wheel (WTD-DUAL, WTT-DUAL) 185.6Calibration of WMs ................................................................ 195.6.1Creating the WM id parameter ............................................................... 195.6.2Writing WM id parameter and WM calibration ........................................... 195.7End of line testing ................................................................ 206TPMS EWM BORDELINE RISKS ................................................ 216.1Ignition hazard risk analysis ................................................... 216.2Borderline risks analysis ........................................................ 21
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 3 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) Abbreviations Abbreviations Explanation DID Data identifier ECU Electronic Control Unit (TPM main control unit) ECU_P Primary ECU on truck ECU_Sx Secondary ECU on trailer(s) EWM External Wheel Module (sensor variant mounted between 2 wheel bolts) MM Main module, main part of EWM P Tire pressure RF Radio Frequency (partly used as synonym for radio[-communication]) TPMS Tire Pressure Monitoring System VM Valve module (part of EWM assembled on tire valve) WM Wheel module (sensor on tire)
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 4 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) Naming Conventions Name Explanation Wheel Module Positioning Procedure to define the position of a wheel module (WM) on a truck or trailer. This defines the tire on which a WM is mounted (belongs to). Trailer Mating Procedure to make a trailer part of a convoy Convoy A truck with one or more trailers Vehicle Unit A single truck or trailer
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 5 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) 1 Revision History Sub-Version Revision: $Rev:: 12424 $ Date Changes (with reference to change request) Author 2015-04-17 First version ready to review Jens Graf / Alan Roue 2015-04-24 Review performed (some findings direct implemented) Review Protocol: Review_Protocol_TPMS_Mounting_Instructions.xls Jens Graf 2015-04-27 Add remarks of Jens done during the review Alan Roue 2015-08-24 Add product references in Scope paragraph Alan Roue 2015-09-15 Add TPMS not safety system §4.4.6 Alan Roue 2017-12-19 Remove P8 and .P08 in front page and scope Add 2 parts statement requested by FCC Part 15.19 (a)(3): could not cause harmfull interference & can accept interferences. §4.4.7 Alan Roue
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 6 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) 2 Scope This Technical Requirements (TR) covers requirements for assembly and calibration process for the Tire Pressure Monitoring System (TPMS) described in table below. For parts specifications, refer to PDM-system (example KOLA), Bill-Of-Material (BOM) or similar. Customer References SKF Reference SKF Designation 21851508 BH-EP-WPM 01 SKF TPMS Electronic Control Unit 21780658 BH-LS-WPM 02E SKF TPMS External Wheel Module 0° 21780660 BH-LS-WPM 01E SKF TPMS External Wheel Module 90° 21780662 BH-LS-WPM 03E SKF TPMS External Wheel Module 135° 21923656 BH-VA-WPM 01E SKF TPMS Counterweight Truck rims covered by this this TPMS mounting instructions are:  Rims of 17.5”  Rims of 22.5”
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 7 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) 3 Preconditions The TPM system will be active (power supplied) in the following vehicle modes:  Pre-Running  Running  Cranking
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 8 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) 4 System description 4.1 System goals The Tire Pressure Monitoring System, TPMS, monitors tire air pressure and temperature and displays the information to the driver through the cluster (integrated system) for commercial vehicles. Overview picture see Figure 1 - TPMS overview. Figure 1 - TPMS overview ECU_P Option Hand Interface ED ECU_S Truck CAN bus External Wheel module EWM Optional Seperate display ED
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 9 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) 4.2 End customer benefits The customer benefits of the system are:  Reduced fuel consumption  Reduced tire wear  Increased safety (reduce risk of tire explosions)  Reduced risk of unplanned stops  Provide a solution for future legislation 4.3 User profiles The following user profiles are foreseen: 1. Driver: The user receives different information from the system: actual tire pressure, under pressure warning, …. 2. Standard service: The user can update system configurations, for example: - Warning thresholds - Vehicle configurations The standard service user profile is typically used in the fleet workshop. 3. Extended service: - The user can read the diagnostic memory - The reset of errors in the diagnostic memory is possible - The Software of the ECU can be updated This extended service user profile is typically used in the OEM workshop or in the OEM production line. 4.4 System applications The following applications of the system are foreseen. 4.4.1 Driving situation During driving the system monitors the pressure and the temperature of the different tires. The tire pressure values are shown on the display. If the tire pressure or wheel temperature is out of normal range, a warning to the driver is initiated. In these system applications also vehicle stop phases are included. Vehicle stop phases are: short breaks, stops for loading/unloading the truck, breaks over a certain time period (for example weekend). Also the connection and disconnection of trailers has to be handled by the system. Two modes are possible. 1. Auto connection: The system determines automatically the connection or disconnection of a trailer. 2. Manual connection: The truck driver supports the system to detect a new connected trailer(s) according to system instructions.
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 10 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) 4.4.2 Configuration by the end customer The configuration by the end customer may be necessary after an error condition, for example a change of a defect system component, after a tire replacement or if a system component has reached its operating lifetime. If a tire(s) or a tire sensor(s) is/are changed the learning of the relative position of the tire sensors in the vehicle is necessary. Two modes are possible: 1. Automatic positioning: The system determines automatically the position of each tire, based on an algorithm which evaluates several sensor data. 2. Manual positioning: The end customer manually positions the tire sensors according to system instructions. If a central receiver on the truck or the optional display is changed or newly installed, the system has also to be learned-in. This configuration is usually done in a truck workshop. 4.4.3 Configuration during truck production During the truck production the wheel sensors are assembled to truck wheels. After this assembly, the system has to be learned-in the positions of the tire sensors. This has to be done manually. If a separate display in the cabin is used, the display must also be paired to the corresponding central receiver on the truck. 4.4.4 Single tire change on road If during driving a tire is damaged and has to be changed on the road, the system automatically assigns the tire sensor to this new tire. The change of a tire on the road is usually done by the driver or by a tire service company. 4.4.5 Maintenance, service by the workshop TPMS EWM is a non reparable module and no software update can be done. Maintenance is also not feasible. Therefore, at module end of life, it shall be recycled by the appropriated means. 4.4.6 Caution Tyre Pressure Monitoring System is not a safety system. Data provided by TPMS system should be consided as informations. TPMS system does not avoid to have a regular tyre pressure maintenance.
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 11 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) 4.4.7 Information to user TPMS complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. Caution: User that changes or modifications not expressly approved by SKF for compliance could void the user's authority to operate the equipment.
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 12 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) 5 TPMS mounting instructions This chapter describes calibration and installation procedures that shall be executed when the TPM system is mounted on the assembly line. Following steps and actions will be necessary to perform a successful installation and configuration of the TPM system. Step Action Expected behaviour 1 Place the TPM ECU in the programming fixture and download the SW package (see 5.1) SW download completed without issues 2 Mount the TPM ECU on the gearbox cross member and electrically connect it to the truck (see 5.2) 3 Mount the appropriate TPM WM variants to the correct wheel and tire air valve (see 5.3) The WMs gets activated (transmitting RF frames) as soon as a pressure leap is detected and as long as the WMs continue to be pressurized. 4 Scan the barcode of the WMs to create a parameter (see 5.6.1) A parameter with the WMs ID-number linked with its position is created and uploaded to the assembly server 5 Write the WM ID parameters to the TPM ECU (see 5.6.2). Parameter programming complete without issues. 7 Check that no DTCs are present at EOL No DTC related to TPMS shall be raised 5.1 SW download The TPM ECU is delivered without SW implemented. Use the manufacturing tools to download the SW package (including parameter dataset). SW download can be performed either by connecting the TPM ECU to interface of the tool used (direct download), or connecting the OBD plug of the truck to the interface of the tool used.
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 13 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) 5.2 Mounting the TPM ECU The TPM ECU is to be positioned on the press screws of the bracket, as shown in Figure 1. Note: Tighten the self-locking nut to 24±4 Nm. Note: Be careful not to touch or damage the ECU connectors during handling. The bracket is to be assembled to the chassis (gear box cross member) in the central part of the vehicle. Figure 1: Example of TPM ECU mounted on Figure 2: Example of the TPM ECU assembled on chassis
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 14 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) 5.3 Mounting the WMs The TPM WM is made up by two modules; the ‘main module’, with the sheet metal bracket and the ‘valve module’, containing the pressure sensor. The two modules are connected to each other by an electrical cable. The ‘main module’ shall be mounted to the rim and fixated by the standard wheel nuts. Make sure the arrow marking on the WM is pointing away from the center of the rim, as illustrated in figure 4 below. Valve module Main module Figure 3: Illustration of the TPM WM (straight connector) and its modules Figure 4: Illustration showing the correct point of direction for the arrow marking
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 15 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) Note: The wheel nuts shall be applied with the tightening torque as specified in TR 1579514 (Volvo standard) The ‘valve module’ shall be assembled to the tire air valve by tightening the swirling nut to the tire air valve hand tight. (Recommended tightening torque approximately 0,3-0,5 Nm) Note: There shall not be any air leakage present when correctly assembled. Air leakage will be detected by the system. Note: Avoid twisting the electrical cable more than 180°. Note: The electrical cable must not be clamped or damaged during the assembly of the WM. The WMs will be delivered in “inactive mode” (=no RF transmission active) and will require activation (switching from “inactive mode” to “active mode”) to enable RF communication and successful calibration. The WMs are activated when a pressure leap is detected, e.g. when getting mechanically connected to a pressurized air valve. As from the point when a WM is initially connected to a pressurized air valve until it gets activated will require 16s. The WMs will stay activated as long as they are pressurized, e.g. connected to an inflated tire. If the pressure is removed, the WMs will switch back to “inactive mode” and that will stop the RF transmission.
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 16 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) 5.4 Front and tag/pusher axle installation with single mounted wheel On single mounted wheels the TPM WM shall be positioned on the two wheel studs closest to the tire air valve, as illustrated in Figure 5 below. Note: Contact between rim/protection ring and electrical cable is permitted. 5.4.1 Counter weight The wheel module must not disrupt wheel balance; therefore, the counterweight shall be mounted on the opposite side (180°) of the TPM WM on all front axles. The curvature of the counter weight shall follow the curve of the rim. Counter Wheel Air valve Figure 5: Illustration showing WM and counter weight assembly on single mounted tires
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 17 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) 5.4.2 Protecting ring Make sure that the wheel protecting ring’s attachment point is clear from the TPM WM. The protecting ring is not to use the same wheel studs as the TPM WM or counter weight. 5.4.3 Light weight pusher axle (WTP-D245) On pusher axles with variant WTP-D245 the TPM WM shall be mounted on the two wheel studs closest to the right next to the tire air valve, as illustrated in Figure 7 below. Figure 4: Illustration pointing out the protecting ring's
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 18 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) 5.5 Rear and tag axle double mounted wheel (WTD-DUAL, WTT-DUAL) On dual mounted wheels the two TPM WMs shall be mounted on the opposite side (180°) of each other. The TPM WMs shall be positioned on the two wheel studs closest to the tire air valves, as illustrated in Figure 8 below. Figure 8: Illustration showing WM assembly on dual mounted tires Figure 7: Illustration showing WM assembly on light weight pusher axle
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 19 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) 5.6 Calibration of WMs Each WM will need to get paired to the TPM ECU and the position defined for successful TPM installation. This is to be done by scanning the barcode of each WM, linked with its position, to create a parameter. The parameter is later written to the TPM ECU on the assembly line, which initiates the pairing of the activated WMs to the TPM ECU automatically. 5.6.1 Creating the WM id parameter Create the parameter by scanning the barcode of each mounted WM and make sure that the WM identification number is linked with correct tire position. Note: The WM’s barcode contains information about WM variant (prefix) and the unique WM identification number, e.g. S 1234567890 Prefix definition: S: Single mounted tire (straight connector) O: Dual mounted tire/Outer wheel (135° connector) I: Dual mounted tire/Inner wheel (90° connector) 5.6.2 Writing WM id parameter and WM calibration Prerequisites to initiate WM calibration:  All WMs must be activated and within RF range to the TPM ECU Write the WM id parameter to the TPM ECU, by using the manufacturing tools, and perform a reset of the TPM ECU. Note: The writing of the parameter can be performed either by connecting the TPM ECU to the interface of the tool used (direct download), or connecting the OBD plug of the truck to the interface of the tool used. Note: Parameter “P1LWM – TPMS Wheel module identification number” is to be used for WM identification.
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 20 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) The WM calibration/pairing will automatically start after the TPM ECU reset. Keep the TPM ECU continuously power supplied for minimum of 3 minutes to allow all WMs to get paired with the TPM ECU. Note: The TPM ECU is power supplied in vehicle modes: Pre-running, cracking and running. Note: Make sure that the power supply to the TPM ECU is not shut off during required time period for above pairing to not cause damages to the non-volatile memory of the TPM ECU. Note: DTC “U300054 – Electronic Control Unit-missing calibration” will be set to inactive when the calibration is completed (all WMs have been paired to the ECU). 5.7 End of line testing Read out the chassis number from the TPMS ECU and check that it corresponds to the vehicle chassis number. Read DTCs from the TPM ECU. Active DTCs shall be remedied and inactive DTCs shall be cleared.
Automotive Development Centre – Sensor Integration Project: Volvo TPMS TPMS Mounting Instructions Author: Alan Roué, Last saved: 2017-12-19 13:33 SVN $Rev:: 12424 $ 21 (21) CONFIDENTIAL (X) / INTERNAL USE ONLY ( ) 6 TPMS EWM bordeline risks 6.1 Ignition hazard risk analysis An ignition risk hazard analysis of SKF Tyre Pressure Monitoring System (TPMS) External Wheel Module (EWM) had been performed following EN 1127-1 : 2011 harmonized standards. Conclusion: All TPMS EWM ATEX risks had been assessed and are limited. 6.2 Borderline risks analysis Following recommendations of ATEX Directive 94/9/EC Guideline – 4th Edition – September 2012 (update December 2013), a borderline analysis had been performed reviewing potential additional risks compared to Ignition hazard risk analysis. All listed items had been reviewed and no borderline risk had been identified. Other potential risks (not listed in ATEX Directive guideline) had been investigated but no other risk had been kept as applicable. Conclusion: No residual ATEX risks are applicable to TPMS EWM.

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