' l

notv1s1ble

Checklist-based
inspection
Information on procedure
for notification prior
to repair

l

il

I,

Finding
CFRP OK

==
== ---==

Repairing screwed
parts+ aluminium
components

Finding
CFRP NOK

Flying technician

CFRP damaged

Diagnostics with
ultrasound camera

CFRP not damaged

AUDI AG

INS

Support strategy for CFRP structural repairs
Process
~

~

~

~

Vehicle check-in
~

Entry of vehicle identification number in Elsa - Information on procedure for
notification prior to repair

~

Preparation of the DISS notification

Diagnostics
~

Inspection based on assessment form (available through Workshop Manual/ Diss)

~

If necessary, call in a flying technician for ultrasound diagnostics

Transportation for repair
~

Commissioning through RB partner (enclosed transportation)

~

Expert assessment of scope of repair prior to transportation

Repair
~

Declaration of cost acceptance by R8 partner

~

Repair of aluminium and CFRP components (vehicle ready for hand-over)

AUDI AG

INS

Support strategy for CFRP structural repairs
Flying Technician - CFK diagnose
~

Ultrasonic testing - DolphiCam
~

~

For non-destructive testing in the workshop, the ultrasonic phased array system
from Dolphi Tech is used.

Ultrasonic testing method
Short ultrasonic pulses are emitted during the test (pulses are between 1 µsand
10 µs). The sound travels through material, is reflected by the rear panel and is
received by the testing head again in the form of an echo. The actual data is
compared with target data to uncover any deviations.

B

A= Material thickness
B = Damage/delamination

,,. DolphiCamrM

~

\

\

C = Fault depth

Audi

Vor·s:prung durch echnlk ~ - -

AUDI AG

INS

Support strategy for CFRP products
Flying Technician - CFRP diagnose
~ Ultrasonic testing - DolphiCam

AUDI AG

INS

Support strategy for CFRP products
Flying Technician - CFRP diagnose

~ DolphiCam data evaluation

0

3

6

9

12

15

18

21

Fault-free area

24

27

30

0

3

6

9

12

15

18

21

24

Area with faulty CFRP

27

30

AUDI AG

INS

Support strategy for CFRP products
Flying Technician - CFRP diagnose

Audi

Vor"Sprong dorel'I iecl'lnlio: .......,...........,..,

AUDI AG

INS

CFRP at Audi partners

AUDI AG

INS

CFRP at Audi partners
Cost evaluation of workplace/tools

('~i !(e r,~'Q

~- Software logarithm based on a defined driving
cycle for monitoring the door lock (lock status)

Driving cycle:

> Ignition on
> Park vehicle

> Drive faster than 10 km/h (counter +1)
> Open the driver door (counter -1)

Malfunction of the door contact switch:

> The end of the driving cycle is not detected
> A counter in the door control unit is incremented by 1
for each new driving cycle started

> When the counter reaches 5, the warning message is
issued

Background to the complaint
A software error in the door control unit causes a
misinterpretation of the driving cycle and therefore an
unjustified error response in the instrument cluster

AUDI AG

INS

Door control unit - Door contact switch monitoring

Affected models
Audi A4 (SW)

AUDI AG

INS

Door control unit - Door contact switch monitoring
Affected models in detail

Audi A3 (8V)

Audi A4 (8W)

Audi Q7 (4M)

General

General

General

> First model with door contact

> 100% KESSY-Go installation

> 100% KESSY-Go installation

Cause of the error

Cause of the error

Cause of the error

> Customer driving profile

> Software error in the

> Software error in the door

switch monitoring

door control unit

control unit
(significantly later
error response vs. B9)

Action

Action

Action

> Customer awareness

> Service measure 96D5

> SVM code 42A004

=> Software solution in development

AUDI AG

INS

Door control unit - Door contact switch monitoring

Summary
Customer complaint
Fault message relating to the parking brake or driver door plus
a warning tone every time the car drives from a standstill
Background for "Door contact switch monitoring"
A software logarithm was written to monitor malfunctions
of the contact switch in the driver's door.
One driving cycle in the vehicle is defined as follows:
> Ignition on
> Drive faster than 10 km/h
> Park vehicle

> Open driver door

If the door lock is defective, the end of the driving cycle is not detected; a counter in the door
control unit is incremented by 1 for each new driving cycle started (when the vehicle is driven
faster than 10 km/h). When the counter reaches 5, the warning message is issued.

Background to the complaint
A software error in the door control unit causes a misinterpretation of the driving cycle and
therefore leads to the unauthorised increase in the counter value.
Action
> Change to the standard software in the door control unit in week 7 /2016

Running gear: Steering wheel heating - function and
diagnosis

AUDI AG

INS

Steering wheel heating - function and diagnosis
Agenda

•

II
II

Initial use and facts on steering wheel heating at Audi

Steering wheel heating: structure and function

Diagnosis

AUDI AG

INS

Steering wheel heating - function and diagnosis
Initial use and facts on steering wheel heating at Audi
First used on the Audi AB D2

> 24°( heating temperature combined with seat heating (no switch provided)
Temperature increase in the model year 2007

> From 24°( to 28°( as well as the introduction of a dedicated switch on the steering
wheel (on the reverse side of the spokes)

Changes on the Audi AB D4

> Activation button moved to the front side of the spokes
Temperature increase in the model year 2015

> From 28°( to 34°(
Flattened steering wheels are not offered with heating
Heat-up duration dependent on the ambient temperature
Steering wheel heating can be personalised for four vehicle keys only

> No function available for the fifth replacement key onwards

AUDI AG

INS

Steering wheel heating - function and diagnosis
Steering wheel heating: structure and function

> Steering wheel structure in five steps
> Base frame> Foam> Heating pad> Foam > Leather cover
> Advantages:
> Improved temperature distribution
> Wires remain hidden after environmental influences
> Steering wheel heating functionality
> Power to the heating pad of the steering wheel via the SCSM*
and coil connector

> Temperature control and regulation takes place in the SCSM
> The temperature sensor is located on the heating pad
> Power to the heating pad between 6-8.SA
> Steering wheel heating has a single stage
* SCSM = steering column switch module (16 - steering column electronics)

AUDI AG

INS

Steering wheel heating - function and diagnosis
Diagnosis
Diagnostic address 16
Measurement value: steering wheel heating
- -~.Offboard Diagnostic Information System Engineering - 6.7.2

Fzg-Projekt: AU49X

(Engineering)

Fzg- Bezeichnung:

Fzg-Verbindung:

Fzg-1D:

Fzg-Status:

Measurement values - display measurement values
Messwert-Name

Steering wheel heating
Temperature
Current, actual value
PWM duty factor
Voltage at the sensor
Voltage at the switch

RDID

10

Wert

r

11

~--+--

Lesen

Adr.

°c

6,40 A

100 %
2,00V
High-Pegel

l

-+-

+-

AUDI AG

INS

Steering wheel heating - function and diagnosis
Video

AUDI AG

INS

Steering wheel heating - function and diagnosis
Conclusion

»

Steering wheel heating can only be operated with four different vehicle keys

»

»
»
»
»
»
»

If a fifth vehicle key is used, the steering wheel heating will not work

Heat-up duration dependent on the ambient temperature
From model year 2015 onwards, the heating temperature is 34°(
(previously 28°()
Flattened steering wheels are not offered with heating
Power consumption is between 6 and 8.SA
Steering wheel heating has a single stage
Function can be activated and diagnosed via the final control diagnosis