CLUTCH AND GEAR SPECIAL FUNCTION


Function Name
 Item Name
 Purpose
 Condition
 Description
Clutch
 Teach In Clutch End Position
 For put into operation of the ASG-system the position of the clutch actuator has to be initialised because of the incremental positioning system.
  • Ignition ON
  • Engine OFF
  • Vehicle speed is zero
  • ASG-Relais ON
  • Battery voltage above threshold
  • No gearbox or engine speed sensor failure
  • Activation of the diagnosis mode by the diagnosis tester via interface
  • Command for teach in clutch position (update rate depends ON the protocol)

 This function teaches in the allowed range of the clutch between engaged (EK) and disengaged (AK) position. The used function is identical to the initialisation function which is used by every ignition ON cycle. The difference is the teach in of both mechanical stops of the actuator (AK and EK). The procedure is time driven and depends on the battery voltage without any other conditions. The learned values will be stored with the next ignition OFF action. In an EOL-process this function has to be executed at first! The function has an exit value which can be evaluated by the tester for interpreting the done action. Four messages are possible:

  • failure
  • range
  • finished
  • active
Independent of the result the measured values will be taken and stored by the next ignition OFF action. Duration: app. 5 seconds
Function Name
 Item Name
 Purpose
 Condition
 Description
Clutch
 Teach In Clutch Touch Position
 Teach in of the absolute value of the touch point when the engine is started for the first time. A lot of the thresholds in the software are depending on the touch point.
  • Ignition ON
  • Engine running and idling
  • Vehicle speed is zero
  • ASG-Relais ON
  • Battery voltage above threshold
  • Gear "N" engaged, gearbox state "shifted"
  • No gearbox or engine speed sensor failure
  • No incremental clutch sensor failure
  • Activation of the diagnosis mode by the diagnosis tester via interface
  • Command for teach in touch point (update rate depends on the protocol)

 The teach in has to be done before and after the first roller test. When no teach in is started the vehicle will drive with an default value which normally leads to a comfortable behaviour of driving (launch, shifting) tending to overshoot of the engine speed during launch and shifting. The adaptation to the correct value will be done continuously over the first time of driving. The first teach in can/will lead to a touch point which is in general to small. This is caused of the clutch because the surface of the clutch disc is still rough and not aligned. After a few actuations of the clutch a setting and aligning will happen. Therefore it makes sense if time is available to activate the teach in again after the first shifts and launching processes on the roller test. In difference to the learn in procedure the teach in is evaluating the absolute value of the touch point. The function has an exit value which can be evaluated by the tester for interpreting the done action. Four messages are possible:

  • failure
  • range
  • finished
  • active
Duration: app. 10 seconds
Function Name
 Item Name
 Purpose
 Condition
 Description
Clutch
 Function Test No1
 This function is implemented to find failures during service work. The actuator is still mounted during the test.
  • Vehicle speed is zero
  • ASG-Relais ON
  • Gear "N" engaged, gearbox state "shifted"
  • Battery voltage above threshold
  • No gearbox or engine speed sensor failure
  • No incremental clutch sensor failure
  • Command for initialisation of the clutch actuator (update rate depends on the protocol)
  • Activation of the diagnosis mode by the diagnosis tester via interface

 To test the function of the clutch actuator the desired value will be set to the engaged and disengaged position for an applicable number of cycles. During the movement of the actuator the deviation between desired and actual actuator position will be measured. If this deviation is bigger than an applicable value or is there a blocking detected, the function test will stop. The desired end position of the function test is the engaged one. The function has an exit value which can be evaluated by the tester for interpreting the done action. Four messages are possible:

  • failure
  • range
  • finished
  • active
Function Test No2
 This function is implemented to find failures during service work. The actuator is still mounted during the test.
  • Ignition ON
  • Engine OFF
  • Vehicle speed is zero
  • ASG-Relais ON
  • Gear "N" engaged, gearbox state "shifted"
  • Battery voltage above threshold
  • No gearbox or engine speed sensor failure
  • No incremental clutch sensor failure
  • Activation of the diagnosis mode by the diagnosis tester via interface
  • Command for initialisation of the clutch actuator (update rate depends on the protocol)

 To test the function of the clutch actuator the desired value will be set to the engaged and disengaged position for an applicable number of cycles. This function is time driven without a deviation control. Because the times for a complete movement are depending on the moving direction, there are two different time thresholds (EK → AK and AK → EK). If the desired end position will not be reached, the function test will stop. The function has an exit value which can be evaluated by the tester for interpreting the done action. Four messages are possible:

  • failure
  • range
  • finished
  • active
Function Name
 Item Name
 Purpose
 Condition
 Description
Clutch
 Function Test No3
 This function is implemented to find failures during service work. It should help to find problems in the wiring harness and/or the ECU.
  • Ignition ON
  • Engine OFF
  • ASG-Relais ON
  • Gear "N" engaged, gearbox state "shifted"
  • Battery voltage above threshold
  • No incremental clutch sensor failure
  • Activation of the diagnosis mode by the diagnosis tester via interface
  • Command for initialisation of the clutch actuator (update rate depends on the protocol)

 A applicable constant voltage is delivered for a applicable time, after this time the polarity will change. The test will stop after one cycle. While the test is active the voltage for the clutch actuator motor has to be measured. Out of it there are 3 failure options:

  1. Voltage on both polarities → actuator or actuator plug failure
  2. No voltage → failure at wiring harness or ECU
  3. Voltage only at one polarity → ECU failure possible
The function has an exit value which can be evaluated by the tester for interpreting the done action. Four messages are possible:

  • failure
  • range
  • finished
  • active
Move to Engaged Clutch Pos.
 For put into operation of the ASG-system the clutch actuator has to be initialised because of the incremental positioning system.
  • Ignition ON
  • Engine OFF
  • Battery voltage above threshold
  • No incremental clutch sensor failure
  • Activation of the diagnosis mode by the diagnosis tester via interface
  • Command for initialisation of the clutch actuator (update rate depends on the protocol)

 This initialisation function sets the EK (engaged) position to a reference value. The used function is identical to the initialisation function which is used by every ignition ON cycle. The procedure is time driven and depends on the battery voltage, but there aren’t any other conditions. The reference value will be stored with the next ignition OFF action. The function has an exit value which can be evaluated by the tester for interpreting the done action. Four messages are possible:

  • failure
  • range
  • finished
  • active
Function Name
 Item Name
 Purpose
 Condition
 Description
Clutch
 Move to Disengaged Clutch Pos.
 For put into operation of the ASG-system the clutch actuator has to be initialised because of the incremental positioning system.
  • Ignition ON
  • Engine OFF
  • Battery voltage above threshold
  • No incremental clutch sensor failure
  • Activation of the diagnosis mode by the diagnosis tester via interface
  • Command for initialisation of the clutch actuator (update rate depends on the protocol)

 This initialisation function sets the AK (disengaged) position to a reference value. The used function is identical to the initialisation function which is used by every ignition ON cycle. The procedure is time driven and depends on the battery voltage, but there aren’t any other conditions. The reference value will be stored with the next ignition OFF action. The function has an exit value which can be evaluated by the tester for interpreting the done action. Four messages are possible:

  • failure
  • range
  • finished
  • active
Initialisation of EEPROM
 The system stores information concerning clutch data, e.g. touch point, creeping adaptation value etc. For the workshop these values can be read out and written for the diagnosis.
  • Ignition ON
  • Activation of the diagnosis mode by the diagnosis tester via interface
  • Command to read touch point
  • Command to read creeping adaptation value
  • Command to read values of adjustment programming
  • Command to write touch point
  • Command to write creeping adaptation value
  • Command to write values of adjustment programming

 During life time the following data will be stored by the system concerning the gearbox:

  • Touch point
  • Creeping adaptation value
These data can be read and erased. One message is possible:

  • Successful (valid)
Remark: By changing the ECU the values related to the clutch are lost. That’s why it is necessary to activate EOL-Service-No.3, 4 and 2 in this case.
Function Name
 Item Name
 Purpose
 Condition
 Description
Clutch
 INIT. of Clutch Protection Data
 The ASG system includes a clutch protection algorithm. The different levels of clutch load which lead to defined actions of the system will be counted and stored. For the workshop these values can be read out for the diagnosis and have to be reset if a new clutch disk is mounted.
  • Ignition ON
  • Activation of the diagnosis mode by the diagnosis tester via interface
  • Command for reading the clutch data protection level 1- 3 (update rate depends on the protocol)
  • Command for reading the clutch data protection counter sum (update rate depends on the protocol)
  • Command for reading the maximum occurred clutch load (update rate depends on the protocol)
  • Command for reading kick down counter (update rate depends on the protocol)
  • Command for writing the clutch data protection level 1- 3 (update rate depends on the protocol)
  • Command for writing the clutch data protection counter sum (update rate depends on the protocol)
  • Command for writing the maximum occurred clutch load (update rate depends on the protocol)
  • Command for writing kick down counter (update rate depends on the protocol)

 During life time the following data will be stored by the system concerning the clutch load:

  • Counter for protection level 1
  • Counter for protection level 2
  • Counter for protection level 3
  • Summation of the clutch load over life time
  • Maximum occurred clutch load
  • Kick down counter
These data can be read and write. The function has an exit value which can be evaluated by the tester for interpreting the done action. One message is possible:

  • Successful (valid)
Remark: By changing the ECU the values related to the clutch are lost. That’s why it is necessary to protocol the clutch related values when the ECU will be changed. Furthermore after each change of the clutch disk the values of the counter have to be reset by the erase function!! Duration: app. < 100 ms
Function Name
 Item Name
 Purpose
 Condition
 Description
Gear
 Switch ASG Relay
 Switch relay for transmission
 -
 -
Start Gearbox Adaption
 Transmission adaptation (Automatic position check for each gear)
 -
 -
Pos. of Shift Drums for SNRCHG
 -
 -
 -