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Lexus diagnostikastendi arvutijuhtimine

Speek, Mihkel (2015) Lexus diagnostikastendi arvutijuhtimine. [thesis] [en] Computerized Control of Lexus Diagnostic Stand.

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Abstract

Lõputöö algas mootori käivitumisprobleemi veaotsingu ja lahendusega (puudus juhtplokiga roolilukk). Juhtmestik oli enamasti märgistamata ja omavahel seotud. Ulatuslikud täiendavad juhtmestiku ja komponentide eemaldamised olid hädavajalikud tagamaks hea ergonoomika ning ruumikasutus. Kasutada olid tehasepoolsed elektriskeemid ja remondijuhend. Mootori juhtploki mõõteadapteri ühendamiseks teostati klemmipaneeli asetuste modifitseerimine, liitmine juhtmestikuga ja põhjalik kontroll. Kontrollpaneeli projekteerimisel tuli arvestada piiratud ruumi, ohutust ja mugavust. Puuduvad lülitid asendati ostutoodetega kontaktskeemide abil. Mõõtekohtade koondamiseks on juhtplokkide, pistikute ja releeplokkide asukohaks stendi tagumine plaat. Arvestatud on mõõtevahendite suurusi, juhtmestiku ulatust ja ülevaatlikkuse tagamist. Kõik kinnitatud komponendid on eemaldatavad. Andmesidevõrgu BEAN ringahelatesse oli tekkinud eemaldamiste käigus katkestused. Terviklikkuse sai taastada õigete ühenduste sildamise teel. Elektrisüsteemi katsetamiseks oli vajalik väljalaske- ja jahutussüsteem, sooritasin nende teostuse lisatööna. Võttes arvesse müra suhtes tundliku elamurajooni lähedust ja seguandurite vajalikke töötingimusi, oli lahendus hoonesisese väljalaskesüsteemi osa teostus. Veenduda tuli kasutada olnud jahutusradiaatori aktiivosa piisavas suuruses ja tagada õhu väljapääs kontuurist. Teostatud on andurite ja täiturite normaalväärtuste ning mõõteadapteri voolutaluvuse kontroll. Mootori veatuli ei süttinud katsetamise käigus, juhtseadmete funktsionaalsus on kontrollitud diagnostikaseadme andmeloendi abil. Lülitite (ostutoode) voolutugevused vastavad normidele. Projekteerisin avariilüliti, arvestades mootoripiduri juhtimise kaasamise võimalust. Stend on läbinud katsed ja tagatud on õppevahendina hea kasutatavus. Süsteemi komplektsuse info on kirjeldatud põhjalikult. Loodud on tingimused, mis võimaldavad järgmiste kursuste tudengitel jätkata stendi projekteerimist ja väljaehitust.

Abstract [en]

The thesis title is „Computerized Control of Lexus Diagnostic Stand”. The current studies about modern engine and automatic transmission diagnostics consist only theory about electrical components and their behavior. For improving the studying process, there is a need for engine stand with real and working components. In our school workshop that kind of stand designing and building has begun. All the technology is taken from Lexus GS300, with production year 2007 and 6-speed automatic transmission. It features modern direct fuel injection, variable timing camshafts, variable length intake and different communication protocols. The current school engine stand technology dates back to 1987 and has no diagnostic scanner readiness, which is essential in moderns car diagnostics. The main goal of this thesis is to design and build electrical control and measuring capability for the stand. Important is to provide ergonomic and easy to understand environment for user. Testing will be done to confirm theory and functionality. I have great interest in car electronics and that is the main reason for choosing this theses topic. It was offered by school and with additional positive sides like granted work room and tools, chance for practical outcome, experienced tutor and modern technology, so I felt that this was just the right task for me. Project started with engine fault finding and repair (electronic steering lock was missing). Wiring harness was mostly unmarked and tied together. Extensive additional removal of wiring harness and components took place. This was necessary to ensure good ergonomics and use of space. Factory electrical wiring diagrams and repair manual was used. For connecting engine control unit to breakout box, the terminals of the box needed modifying, then cables could be soldered and checked properly. The control panel was designed with considering of limited space, safety and comfort. Missing switches were replaced using information from electrical wiring diagrams. Control units, plugs and relay blocks are placed onto the rear panel of the stand to concentrate measuring terminals and they are all removable. Measuring tool size, wire lengths and ergonomics were taken into account in installation process. There were open circuits in BEAN communication lines due to removal of control units. Repairing of these communication loops took place. Exhaust and cooling systems were necessary for electric system testing, it was extra work for me. Because of the sound-sensitive residential area was close and air-fuel sensor-specific exhaust environment was needed, decision was made to construct indoor part of the exhaust system. Non-genuine coolant radiator was used after confirming fair core dimensions and air bleeding capability. Sensor and actuator normal condition check and breakout box current capability check was completed. Check engine light did not activate during the tests, user input devices functionality was confirmed using diagnostic scanner. All replacement switches have enough current capability. Emergency switch was designed, also using the engine load device capability to enhance safety. The engine and gearbox stand has successfully completed testing. Good ergonomics are granted for future students. In this thesis, all the necessary information about stand electric system modifications is available. For future students theses, reasonable conditions have been made.

Item Type: thesis
Advisor: Aimar Lukk
Subjects: Transport > Automotive engineering > Car construction > Car electrical systems
Transport > Automotive engineering > Car construction > Internal combustion engine
Divisions: Institute of Engineering > Automotive Engineering
Depositing User: Mihkel Speek
Date Deposited: 18 Jun 2015 08:16
Last Modified: 18 Jun 2015 08:16
URI: http://eprints.tktk.ee/id/eprint/1007

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