Silicon Optical Modulators Recent developments in fabrication of High Speed Modulators Jee290f.
2006 CITA CONFERENCE - vr.org.vn WORKSHOP 7.pdf · vehicles.So more than 70 different tests were...
Transcript of 2006 CITA CONFERENCE - vr.org.vn WORKSHOP 7.pdf · vehicles.So more than 70 different tests were...
2006 CITA CONFERENCE2006 CITA CONFERENCE‘‘The future of Vehicle Inspection The future of Vehicle Inspection –– Contributing to Sustainable Contributing to Sustainable
Road Transport’Road Transport’‘Developments in Inspection of 2 & 3 Wheeled Vehicles‘Developments in Inspection of 2 & 3 Wheeled Vehicles’’
WORKSHOP WORKSHOP 77
Emerging Technologies and their Impact on Emerging Technologies and their Impact on Vehicle InspectionVehicle Inspection
Chairperson :Chairperson : Mr. Mr. Eduard FernandezEduard FernandezSecretarySecretary : Mr. : Mr. Toni ViscidoToni Viscido
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Safety & Environment
Sustainability
Road Transport
In-service Vehicle Inspection
Agenda1- Opening
2- Speakers IntroductionMr. Mäurer from DEKRA, GermanyMr. Van Calker from FSD GmbH, GermanyMr. Viscido from CITA, BelgiumMr. Salvachua from Applus+, Spain
3- Questions & Answers
4- Summary and Conclusions
5- Closure
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
‘‘The future of Vehicle Inspection The future of Vehicle Inspection –– Contributing to Sustainable Road Contributing to Sustainable Road Transport’Transport’
‘Developments in Inspection of 2 & 3 Wheeled Vehicles‘Developments in Inspection of 2 & 3 Wheeled Vehicles’’
2006 CITA CONFERENCE2006 CITA CONFERENCE
WSH 7 WSH 7 -- PAPER 1PAPER 1
Scan Tools use for Technical Scan Tools use for Technical InspectionsInspections
HansHans--JürgenJürgen MäurerMäurerDEKRADEKRAGermanyGermany
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
5
Scan tools use for Technical
Inspections
AP4, Prüftechnik EntwicklungHans-Jürgen Mäurer, Gunter Geßner
Contents
• Vehicle Technology
• DEKRA diagnostic tool test
• Use of scan tools for periodical technical inspection (PTI)
• Test pyramid
• Summary
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Vehicle Technology
Increasing number of safety critical electronic systems:Airbags, ABS, ESP, Advanced Driver Assistance Systems (ADAS)
MIL Only the CARB Connector is
standardizedFor most of the systems no regulation is existing;Neither for type approval nor for periodical technical InspectionMal function information for the driver is also not standardized.
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
DEKRA diagnostic tool test 2003
Test was done on8 scan tools with 9 vehicles
AVL, BOSCH, TECNO,TECHMESS, GUTMANN,SUN, TEXA und WÜRTH
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
DEKRA diagnostic tool test 2003
Tested vehicles
Manufacturer Type Cylinder capability (l)
Power (kW) Fuel Date of first registration
BMW 320i 2,0 110 Otto 05.2000Citroen Xantia 1,9 66 Diesel 04.1999Opel Astra 1,8 92 Otto 05.2002Mazda 626 2,0 85 Otto 03.1999Mazda 6 1,8 88 Otto 07.2003Mercedes C 220 CDI 2,1 105 Diesel 09.2003Renault Twingo 1,2 43 Otto 03.2003VW Golf IV 1,4 55 Otto 09.2000
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
DEKRA diagnostic tool test 2003
What was done
Key element for every use of scan tools is identification of vehicle – system – and version Without this important step, the reliability of the ongoing steps is not 100%.Comparison of number of available vehicle systems which can be tested.Capability to find an simulated failure on the vehicles.So more than 70 different tests were done
Using the universal and standardized CARB connector
Benchmarking was the available OEM – Tool function for each different Vehicle
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
DEKRA diagnostic tool test 2003
Results
Example for the available diagnostic function for a specific vehicle (BMW 320i)
I: Identification F: Trouble code read out FL: delete IW: Real time values read out S: actuator activation
DEKRA diagnostic tool test 2006
The second test was done on• 10 scan tools• 10 vehicles
Actia, AVL, BOSCH, Gutmann, Lunch, SUN. Techmess, Texa, Tecno, Würth,
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
DEKRA diagnostic tool test 2006
Tested vehicles
Manufacturer Type Cylinder capability (l)
Power (kW) Fuel Date of first
registrationBMW 318i 1,9 87 Benzin 03/2001Peugeot 206 1,4 55 Benzin 01/2003VW Golf IV 1,4 55 Benzin 05/2003VW Passat 2,0 TDI 100 Diesel 07/2004Ford Focus 1,8 TDCi 85 Diesel 04/2002Mercedes A 168L 1,6 75 Benzin 05/2003Mercedes C 200 2,2 CDI 90 Diesel 05/2004Opel Astra G 1,6 62 Benzin 07/2002Opel Corsa B 1,0 40 Benzin 12/1997Mazda 626 2,0 85 Benzin 11/2000
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
DEKRA diagnostic tool test 2006
What was done 1. Test of available vehicle systems (ABS, ESP….)2. Diagnosis depth,(Read of DTC, Real time values…3. Diagnosis quality, (number of available data….)
1. Help functions for repair2. Soft ware update service new vehicles3. Expert hotline trouble desk4. Technical solution of the tool (Hardware solution)
More than 100 tests were done, with simulation of failures and comparison with OEM tools.
Additional evaluations for
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
DEKRA diagnostic tool test 2006
ResultsMost of the tested tools were able to cover ahigher number of vehicles from different manufacturers,
Functions like: Identification, Trouble code read out / delete, Sensor real time values, actuator activation e.g. become available for much more systems, also for new vehicles
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
DEKRA diagnostic tool test 2006
Results
Example for the evaluation of results for one specific vehiclein this case for Peugeot 206
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
DEKRA diagnostic tool test - comparison
Difference between both tests over all systems/vehicles
Test 2003
0
5
10
15
20
25
BMW 3er Mercedes C- Class
Opel Astra VW Golf IV Mazda 626
Num
ber
of s
yste
ms
total systemsaverage of found systems
Test 2006
0
5
10
15
20
25
BMW 3er Mercedes C -Class
Opel Astra VW Golf IV Mazda 626
Num
ber o
f sys
tem
s
total systemsaverage of found systems
Absolute number of systems increased and also the data for vehicle systems
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
DEKRA diagnostic tool test - comparison
DevelopmentComparison - test 2003 and 2006
0,010,020,030,040,050,060,070,080,090,0
100,0
BMW 3er Mercedes C -Class
Opel Astra VW Golf IV Mazda 626
foun
ded
syst
ems
(%)
20032006
Relation is becoming better, but some special cases are also to be mentioned VW and MAZDA
Over all results of the tests
Key findings from the last test• Obviously improved performance• New hardware solutions like wireless data communication• Diagnostic data also for new vehicles available• All tested scan tools have been more efficiently since the
first test• Beside customized solutions also Standard PC‘s with
standard software are more available, therefore standard software and data exchange become more easy and comfortable
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Options for future use of scan tools for periodical technical inspection
Technical Inspection on vehicles generally contents of
Visual Inspection – Function Test – Efficiency Test
For the test of electronically controlled systems, new measures should be taken into consideration.Use of scan tools for enhances procedures should be considered
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Options for future use of scan tools for periodical technical inspection
For periodical technical inspection (PTI) it is the first step to identify the vehicle which is on test correctly.
This is also to make sure, no changes which can effect the safety behaviour of the vehicle has occurred.
To ensure the build in safety of every vehicle, the original fitment and function of subsystems should be evaluated.
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Test pyramid
1. Vehicle and System identification
It is of high importance to identify correctly the vehicle and the subsystems build in
A database which stores all vehicles with standard equipment and also any additional fitment which is needed.
In Germany a fist step has been done with the Vehicle System Data (FSD).
This database is used for a regular PTI procedure for vehicles built 2006 or later.
FSD
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Test pyramid
2. System behaviour test/MIL - visual inspection
Second step is to check all the MIL – Indicators for the on board information on the system behaviour;
MIL = Mal function Indicator Lamp
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
To days status of scan tools useful for PTI purposes
Test pyramid
3. Trouble code read outThe read out of trouble codes for all safety relevant systems.
It is important to compare the stored data with the displayed system status (MIL)
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
To days status of scan tools useful for PTI purposes
Test pyramid
4. Read out of real time values
The sensors, actuators, wires, connectors and the CPU are included by this test step
A good example is given for the wheel speed sensors and pressure modulators at ABS/ESP –Systems
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
To days status of scan tools useful for PTI purposes
Test pyramid
5. Active test of actuators / system
The combination of already existing equipment, such as a roller brake tester, and modern scan tools can support a highly efficient and reliable test result.
For a 100% solution on every new vehicle a standardisation is required.
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Special requirements for the use of scan tools for PTI
For Garage use scan tools are more diagnostic tools,
Find a failure and repair it as fast as possiblefor all systems (comfort and safety/environmental related)
For PTI we have just to evaluate the system behaviour,For only safety / environmental related Systems;
no repair, no detailed failure analysis, no wiring diagram needed, but it should cover most of the vehicle fleet;
For the vehicle after 2000 the CARB connector is standard, so approximately 80% of the relevant systems might be accessible
Summary Strong development on universal generic scan toolsNumber of available vehicle data and systems increased (more than 80% of Model year 2000 or later - iDELSY)
• New cars will also be available earlier • The depth of functions has also increased• The quality of help an hotline services is improved
For PTI purposes Scan tools will become very important to adapt measures and methods for modern vehicle systems, in combination with well applied methods. The requirements for PTI are much different than for garage use; no diagnostic functions are needed, clear identification and communication for all vehicles is the main target
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Safety & Environment
Sustainability
Road Transport
In-service Vehicle Inspection
Agenda1- Opening
2- Speakers IntroductionMr. Mäurer from DEKRA, GermanyMr. Van Calker from FSD GmbH, GermanyMr. Viscido from CITA, BelgiumMr. Salvachua from Applus+, Spain
3- Questions & Answers
4- Summary and Conclusions
5- Closure
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
‘‘The future of Vehicle Inspection The future of Vehicle Inspection –– Contributing to Sustainable Road Contributing to Sustainable Road TransportTransport’’
‘‘Developments in Inspection of 2 & 3 Wheeled VehiclesDevelopments in Inspection of 2 & 3 Wheeled Vehicles’’
2006 CITA CONFERENCE2006 CITA CONFERENCE
WSH 7 WSH 7 -- PAPER 2PAPER 2
Inspection of Electronic Components Inspection of Electronic Components within PTI in Germanywithin PTI in Germany
JJöörgrg Van Van CalkerCalkerFSD GmbHFSD GmbHGermanyGermany
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Agenda
11 About FSD GmbH
22 Motivation
33 Legal foundation
44 Test concept
55 Process
66 Software
77 Outlook
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
FSD GmbH
Association of allinspection organisations
in Germany*
Governmental mandate andCommon business purpose:
To provide practicable test methods for electronically equipped
vehicle systems for PTI
AboutFSD GmbH
1
*with the exception of one very small organisation, GTS
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Agenda
11 About FSD GmbH
22 Motivation
33 Legal foundation
44 Test concept
55 Process
66 Software
77 Outlook
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Accident avoidance potential of advanced driver assistant systems
Influencable accidents with serious personal injuries in Germany (2004 approximatley 65.000 total)
Advanced driver assistant systems Rate [%] Number 1),4)
MotorcyclesAnti Lock Braking System 1) 10 3.600
Passenger CarsElectronic Stability Program 1) 10 bis 15 5.000 bis 7.500Adaptive Cruise Control 1),2) 6 3.000Lane Departure Warning System 1),2) 4 2.000Predictive Brake Assist 2) 57 28.000Lane Keeping Support 2) 20 10.000
Vans / Pick-up TrucksElectronic Stability Program 1) 10 360Rear View Camera1) 5 180
TrucksRear View Camera 1) 1 50Turn off assist 1) 3 150Side Collision Warning 1) 3 150Electronic Stability Program 1),3) 9 450Adaptive Cruise Control 1),3) 6 300Lane Departure Warning System 1),3) 4 400Predictive Brake Assist + ACC 3) 21 1.050LDW + Lane Keeping Support3) 10 500
Sources:1) Institute for Roadtraffic by GDV (Germany), Gwehenweger,and other, 20032) University Regensburg (Germany), Dissertation Gründl, 20053) Safety Truck, MAN + DaimlerChrysler, 20064) Calculation by arge tp 21 on basis of approximately 65.000 accidents of serious personal injuries in 2004 and 80.000 light personal injuries and 6.000 killed persons
Motivation
2
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Risk: Decrease of the accident avoidance potential over time
The testing of electronically controlled systems is not included in the „PTI - “ directive 96/96/EC today.
With defects, abrasion and manipulation as well as cost-driven demounting after defects or accidents - unnoticed in the course of PTI -the safety level of the vehicle may decrease significantly over time.Motivation
2
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Agenda
11 About FSD GmbH
22 Motivation
33 Legal foundation
44 Test concept
55 Process
66 Software
77 Outlook
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Overview
With the inspection of safety relevant electronically controlledsystems in the frame of directive 96/96/EC it is possible to ensurethe original safety level of the individual vehicle over its lifetime.
Legalfoundation
3In appreciation of its potential for increasing roadworthinessGermany decided to introduce this kind of inspection as pilot for Europe. Continuous reports of the won experiences will be submitted to the Commission, and could serve as a basis for future Community regulations.
In Germany the new inspection is integrated into the regular PTIsince April 1st 2006
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Scope
In Germany the inspection of electronically controlled systems within the PTI is mandatory by law for
all cars with a date of first registration of 01.04.2006 or later.
all vehicle types
all systems of 8 security relevant system classes (next slide)Legal
foundation
3
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Relevant vehicle system classes
Braking systems
Steering systems
Headlights and lights
Seat belts or other restraining devices
Airbags
Rollover-protection features
Driving dynamics systems which affect the braking system
Speed limiters
1
2
3
4
5
6
7
8
Legalfoundation
3
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Agenda
11 About FSD GmbH
22 Motivation
33 Legal foundation
44 Test concept
55 Process
66 Software
77 Outlook
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Test concept - boundary conditions
Being part of the PTI the test is subject to the following conditions
sufficient reliability
easy integration in the existing test process
acceptable requirements in time or costs
General conditions
Legalfoundation
3
Because of the specific inspection infrastructure in Germany (10.000 inspectors, 65% of the inspections in 40.000 garages) this means, at least for the starting years, that:
expensive special testing equipment (e.g. a handheld tester) should not be required
the test has to be practicable in garages as well as in inspection centres
the new test should not last longer than 1 minute per system
Special conditions in the beginning (2006)
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Test concept 2006 - overview
Information about built-in relevant
systems
Information for manual
identification
Test methods
ManualIdentification
test
Functiontest
Testconcept
4
Information providedfor the test
Test elementsat the beginning
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Information about built-in systems
Reference Vehicle identification number
Content Designation of the systems and subsystems
Example
Testconcept
4
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Information for manual identification
Reference System (often also model-specific)
Content Illustrations and verbal descriptions supporting the visual identification of systems
Testconcept
4Example
(S9)
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Test methods
Reference System (often also model-specific)
Content Algorithmic description (list of test steps) of the test method including defect conditions
Testconcept
4Example
next slide
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Test methods (cont.)
Example (extract)
(S9)
Testconcept
4
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Manual identification test
Test, if all systems listed in the Information about built-in relevant systems are still present in the vehicle or might have been illegitimately removed using the provided identification information.
Characterisation
Testconcept
4
Information about built-in relevant
systemsall systems still present?
Information for manual
identification
if not, this is a irregularity,commonly classified as defect
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Function test
Types of function tests in 2006
Check of MIL
Function tests with existing test equpiment(roller brake dynamometer)
Testconcept
4
Information about built-in relevant
systemsFunction
test
Test methodsdefectno defect
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Special aspects – Test drive
Test drive > 8 km/h
To activate the control function of electronically controlled systems often a test drive with low speed is required
Testconcept
4
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Special aspects – Combined test methods
To avoid duplication of test actions, the different test methods for the built-in systems are integrated and combined as far as possible
Combined test methods
Testconcept
4
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Agenda
11 About FSD GmbH
22 Motivation
33 Legal foundation
44 Test concept
55 Process
66 Software
77 Outlook
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Process overview
Testing software(standardized)
manufacturer/importer
PTI Organisations (FSD GmbH)
inspector
manufacturer/importer
manufacturer/importer
Test methods (standardized)Provision of
vehicle and system
information
Development, validation and
standardisation of test methods
cooperate
3
21
Development of testing software
Process
5
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Step 1: Provision of information by manufacturers
manufacturer/importer
manufacturer/importer
manufacturer/importer
Provision of vehicle and
system information
1
Technical system information
Process
5
information about built-in systems for individual VIN
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Step 2a: Development and validation of test methods
PTI Organisations (FSD GmbH)
Development, validation and
standardisation of test methods
2
Development of testing software
Built upon the gained system knowledge practicable test methods are created and validated by the PTI
Organisations (FSD) in cooperation with the manufacturers / importers.
The validation comprises thorough tests with one or more exemplars of the vehicle modelProcess
5
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Step 2b: Standardisation of test methods
PTI Organisations (FSD GmbH)
2
Validated System data is integrated into a standardised data model with uniform structure, format and
representation (including illustrations and formulations)
Development, validation and
standardisation of test methodsProcess
5
Development of testing software
database
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Step 3: Access to test methods
inspector
3
Easy and standardized access to test methods (online / offline), with integration into the testing
software of the inspection organizations
Process
5
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Step 3: Access to test methods
1. Invocation of the list of all built-in relevant systems directlyfrom the testing software
Process
5
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Step 3: Access to test methods
Call of the infor-mation for manualidentification and test method by click in the system list
2.
Process
5
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Agenda
11 About FSD GmbH
22 Motivation
33 Legal foundation
44 Test concept
55 Process
66 Software
77 Outlook
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Access to test methods during PTI today
CompleteTest methods
(Notebook)
Execution ofinspection
„Summary“may be printed
Software
6
Memory
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Test summary
For situations, where the notebook can not be present at the time of the inspection, a summary of all test methods for a specified vehiclecan be printed out on one sheet of paper
Software
6
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
More efficient access to test methods during PTI tomorrow
Access to the completetest methods on PDA, UMPC, Smartphone orWeb tablet
by wireless data transferor remote access to the notebook
Software
6
CompleteTest methods
(Notebook)
Execution ofinspection
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Test method layout on PDA / Smartphone
Information about built-in systems
Summary
Software
6
Complete testmethods
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Demonstration
Software
6
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Agenda
11 About FSD GmbH
22 Motivation
33 Legal foundation
44 Test concept
55 Process
66 Software
77 Outlook
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Example for possible later extensions of the test concept
Information about built-in relevant
systems
Information for manual
identification
Test methods
ManualIdentification
test
Outlook
7Function
test
Automaticidentification test
Information to be extendedfor the additional test
Possible additionaltest element
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
Automatic identification test
The notebook of the tester will be connected with the vehicle (e.g. by a cable or wireless gateway to the OBD system). Based upon the digital identification of the built-in systems provided as system data the search for the systems is carried out automatically.
Characterisation
Outlook
7
Information about built-in relevant
systemsall systems still present?
connection to thevehicle
if not, this is a irregularity,commonly classified as defect
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Inspection of electronic
components within PTI in Germany
End
Thank you for your attention !
Safety & Environment
Sustainability
Road Transport
In-service Vehicle Inspection
Agenda1- Opening
2- Speakers IntroductionMr. Mäurer from DEKRA, GermanyMr. Van Calker from FSD GmbH, GermanyMr. Viscido from CITA, BelgiumMr. Salvachua from Applus+, Spain
3- Questions & Answers
4- Summary and Conclusions
5- Closure
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
‘‘The future of Vehicle Inspection The future of Vehicle Inspection –– Contributing to Sustainable Road Contributing to Sustainable Road TransportTransport’’
‘‘Developments in Inspection of 2 & 3 Wheeled VehiclesDevelopments in Inspection of 2 & 3 Wheeled Vehicles’’
2006 CITA CONFERENCE2006 CITA CONFERENCE
WSH 7 WSH 7 -- PAPER 3PAPER 3
New PTINew PTI--Requirements for the Requirements for the Inspection of Hybrid Electric VehiclesInspection of Hybrid Electric Vehicles
Toni ViscidoToni ViscidoCITACITABelgiumBelgium
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
©
251981 - 2006
New PTI-Requirements for the Inspection ofHybrid Electric Vehicles
12th CITA ConferenceHanoi, Vietnam
Dipl.-Ing. T. ViscidoForschungsgesellschaft Kraftfahrwesen Aachen mbH
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
©
251981 - 2006
Institut für Kraftfahrwesen Aachen Forschungsgesellschaft Kraftfahrwesen
mbH
Research & Development
ANGEWANDTE FORSCHUNG, ENTWICKLUNG UND CONSULT
FORSCHUNGSGESELLSCHAFTKRAFTFAHRWESEN mbHAACHEN
INSTITUT FÜRKRAFTFAHRWESENAACHEN
Body Electronics
Chassis Powertrain Acoustics
Driver Assistance
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
©
251981 - 2006HEV-Working Fields
Tech
nica
lBen
chm
arks
Dev
elop
men
t Pro
cess- Concept Development
- Simulation- Operation Strategies- Controller Hard-/Software- Prototype Vehicles- Testing- Technical Benchmarks
©
251981 - 2006Development of Systemarchitecture
Implication factors
Driving Dynamics
ADAS
„Predictive Driving“
Brake-SystemsHybrid-Powertrain
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
©
251981 - 2006Systemarchitecture
Sensorconfiguration for “Predicitive Driving”
VideoSystem
mediumrangeRadarThales
Laser-Scanner
IBEO
shortrangeRadarSAAB
Steuergerät
LidarTEMIC
©
251981 - 2006Systemarchitecture
Development of Function Integration
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
©
251981 - 2006HEV - Toyota Prius 2
Battery incl. BMS and Fusing
ICE
E-Motor
Powerelectronics incl. DC/DC-Converter
Powerdistribution(mechanical)
Generator
Source: Toyota
HV-Harness
EPS
Electronically Controlled Brakesystem (ECB)
©
251981 - 2006HEV-System
ECU
MC
U
TCU BMS
Verbrennungsmotor GetriebeE-M
otor
High-VoltageBatterie
HCU
Kommunikation
12VBatterie
DC Leistungs-elektronik
DC12VAUX
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
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251981 - 2006Components of HEV-Systems
Integrated E-Machine (ISG with 2 clutches)
6000rev/minMaximum speed2000rev/minBase speed15kWContinuous power120NmLow-speed peak torque108VMinimum battery voltage197mmRotor lamination bore284mmStator lamination diameter
6000rev/minMaximum speed2000rev/minBase speed15kWContinuous power120NmLow-speed peak torque108VMinimum battery voltage197mmRotor lamination bore284mmStator lamination diameter
15 kW ISG Reluctancemachine
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
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251981 - 2006Components of HEV-Systems
Motor Inverter and DC/DC-Converter
Toyota Prius II
Toyota RX 400h BRUSA
SEMIKRON
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
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251981 - 2006Components of HEV-Systems
NiMH-Battery Toyota Prius II
9 Modules(64,8 V)
19 Modules(136,8 V)
=> 187,5A @182 V => 34 kWEmegrency Switch withintegrated Fuse
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251981 - 2006Components of HEV-SystemsHV-Powernet / -Harness / -Plugs / -Fuses
Voltages up to 500 VDCCurrents up to 400 ATemperatures up to 100°C
=>Cross section up to 120 mm²
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
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251981 - 2006PTI for Hybrid Vehicles
PTI ensures functionof...
Component Protection- Overvoltage and shortcirciuts
- Lightarcs
- Over- and Undervoltages
Occupant Protection- Isolation Protection
- Detection in case of contact
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
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251981 - 2006Development of Safety Concepts for HEV
Legislation/Standards
Übergeordnet: DIN EN 61140 (VDE 0140 Teil 1)Beschreibt Maßnahmen zum Schutz gegen elektrischen Schlag und gemeinsame Anforderungen für Anlagen und BetriebsmittelBasiert auf IEC 61140:1997-08 “Protection against electric shock, common aspects for installation and equipment”Anwendungsbereich: Anlagen, Systeme und Betriebsmittel bis AC 1000 V und DC 1500 VGrundsätze:
Gefährliche aktive Teile dürfen nicht berührbar seinBerührbare leitfähige Teile dürfen nicht elektrisch aktiv sein
Bezogen auf Elektrofahrzeuge:ISO 6469 „Elektrische Straßenfahrzeuge – Sicherheitsspezifikationen“
Teil 1: Bordeigene elektrische EnergiespeicherTeil 2: Funktionelle Sicherheitsvorkehrungen und Schutz gegen FehlerTeil 3: Schutz von Personen gegen elektrische Gefahren, incl. Tech. Corrigendum
ISO 8713: „Electric Road Vehicles – Vocabulary“ISO 8714: „ERV – Reference Energy Consumption and Range, Test Procedures”ISO 8715: „ERV – Road Operating Characteristics“DIN EN 61851 / VDE 0122 / IEC 61851
Teil 1: „Allgemeine Anforderungen“Teil 2-1: „Anforderungen eines Elektrofahrzeuges für konduktive Verbindung an AC/DC-Versorgung“Teil 2-2: „Wechselstrom-Ladestation für Elektrofahrzeuge“
Bezogen auf Elektrofahrzeuge:IEC 60479-1 (1994-09), IEC 60664-1 (2000-04), Direktive 73/23/EEC
Zu beachtende Sicherheitsmaßnahmen bei DC-Spannungen >75V
IEC 61557-8 (1997-02)Isolationsüberwachung in IT-Teilnetzen bis 1000VAC/1500VDC
UL 2231Personenschutz in Versorgungskreisen von Elektrofahrzeugen
EN1987, Teil 3Personenschutz im Falle einer Batterie-Fehlfunktion
DIN VDE 0122, Chapter 4.3.5.5Mechanische Ansprüche an das elektrische System eines Elektrofahrzeuges, zulässige Kabelverlegungen
DIN EN 50272-3Sicherheitsansprüche an Traktionsbatterien
Bezogen auf Elektrofahrzeuge:EN ISO 8092, Teil 2
Zugfestigkeit von Kabeln, Wasserdichtigkeit von Steckverbindern
DIN ISO 3808, part 1Hochspannungs-Zündleitungen
DIN 72 551, part 5Niederspannungs-Zündleitungen
SAE J1742Hochspannungs-Steckverbinder, Testmethoden und grundsätzliche Qualitätsansprüche
SAE J1127, SAE J1673, SAE J1654Hochspannungs-Kabelbäume
IEC/TR 60783Kabelbäume und Steckverbinder für Elektrofahrzeuge
Very extensive Standards!
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
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251981 - 2006Safety Concepts for HEV
main conclusions of standards
fka-expertise: filtering/analysis of relevant standards
Faultmanagement for HV-Powernet in
Faultcase (Accident etc.)
Isolation Monitoring of HV-PowernetBattery-
Overcurrent-Safety concept
Protection of wires and connectors due
to light arcs
HEV-Powernet
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251981 - 2006Safety Concepts for HEV
typical HEV-Powernet
Categorisation of Powernet in 3 Subsystems:DC- HV Powernet Dangerous Voltages >60VAC- HV Powernet Dangerous Voltages >60V14V- LV Powernet Non-Dangerous Voltages <60V
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251981 - 2006PTI for Hybrid Electric Vehiclescomponents to be inspected to insure safety
Within the framework of a PTI the following components are recommended to be inspected:
Leak tightness and check of damages of HV-harness and connectors (due to e.g. lightarcs)
@ HV-Battery@ Inverter@ E-Machine@ DC/DC-Converter
Efficiency of Isolation Monitoring generation of isolationfault, monitoring MUST detect this fault
Function of Emergency Switch, if existingProtection must always be given through intact housing of HV-components
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
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251981 - 2006Contact
Dipl.-Ing. Toni Viscidofka – Forschungsges. Kraftfahrwesen Aachen
mbHSteinbachstr. 7D-52074 Aachen, GermanyTel: +49 / (0)241 / 8861-121Mobil: +49 / (0)163 / [email protected]
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Safety & Environment
Sustainability
Road Transport
In-service Vehicle Inspection
Agenda1- Opening
2- Speakers IntroductionMr. Mäurer from DEKRA, GermanyMr. Van Calker from FSD GmbH, GermanyMr. Viscido from CITA, BelgiumMr. Salvachua from Applus+, Spain
3- Questions & Answers
4- Summary and Conclusions
5- Closure
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
‘‘The future of Vehicle Inspection The future of Vehicle Inspection –– Contributing to Sustainable Road Contributing to Sustainable Road TransportTransport’’
‘‘Developments in Inspection of 2 & 3 Wheeled VehiclesDevelopments in Inspection of 2 & 3 Wheeled Vehicles’’
2006 CITA CONFERENCE2006 CITA CONFERENCE
WSH 7 WSH 7 -- PAPER 4PAPER 4
WIM WIM –– Weigh in MotionWeigh in Motion
Victor SalvachuaVictor SalvachuaApplusApplusSpainSpain
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
Weigh In Motion Systems (WIM)Application on enforcement strategies
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion SystemsWeigh In Motion Systems
Summary01_ Background02_ System description 03_ Application on enforcement strategies04_ System results05_ Conclusions
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
Overloaded vehicles represent a roadworthiness problemOwn vehicle safety is reduced if vehicle is overloaded
Vehicle StabilityMisuse of different vehicle systems (Brake, suspension, tyres…)Possible load displacement / FallUnexpected slow vehicles (Rear-end collisions)
Trucks accidents represent a safety problem for other road usersIncrease on the pollutant emissions of overloaded vehicles
01_ Background
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
Weight enforcement strategies require real traffic data to be effectiveStatic scales present different disadvantages:
Low capacity (vehicles/hour)Fixed locationsHigh installation/maintaining costsBurden on compliant drivers
01_ Background
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
WIM: “Weigh In Motion”
Weigh-in-motion (WIM) is defined as the process of estimating a moving vehicle’s gross weight by measurement and analysis of dynamic vehicle tire forces (ASTM).
It allows vehicles to be weighed as they are moving across the scale at speeds from 0-130 km/h
02_ Description
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
WIM: “Weigh In Motion”WIM system is divided in several components:
Weight sensors (installed on the road surface)Cabling to connect the weight sensors to the computerComputer interface to convert scale readings to real weightPC Software to perform reading calculations and store the data
02_ Description
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
WIM: “Weigh In Motion”Some additional components can be installed in order to increase
the system capabilities:Axle sensor (Allowing vehicle type recognition)Vehicle height sensor (Allowing size enforcement)Vehicle speed sensor (Allowing speed enforcement)AVI (Automatic Vehicle Identification) (Allowing single vehicle
recognition)
02_ Description
Mettler: www.mtwim.com
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
WIM Classification (ASTM Types): American Society for Testing and Materials (ASTM E 1318-02)
System classification
Speed range
Accuracy
Application
Installation requirements
Calibration procedures
02_ Description
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
WIM Classification (ASTM Types):
Tolerance for 95 % Probability of conformity
02_ Description
Type I Type II Type IIISpeed Range 16-128 km/h 24-128 km/h 16-128 km/hAccuracy (%) (%) (%) Weight (Kg) (± kg) [%]
Wheel Load ± 25% n.a ± 20% 2270 140 [6%]Axle Load ± 20% ± 30% ± 15% 5450 225 [4%]Axle Group Load ± 15% ± 25% ± 10% 11300 550 [5%]G.V.W ± 10% ± 15% ± 6% 27200 1130 [4%]
Application Traffic Data collection
Traffic Data collection
Weight Enforcement
Type IV3 - 16 km/h
Weight Enforcement
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
WIM Classification (ASTM Types):
Types III & IV are the ones with a direct application on enforcement methods but the data collection capabilities offered by types I & II should also be considered
02_ Description
Type I
Type II
Type III Screening
Type IV Low Speed WIM Enf. Scale
High Speed WIM
Data Collection
Enforcement
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
WIM Classification (Sensor technology):
Piezoelectric sensorMeasurement based on piezoelectric effect
(stress) (Piezoceramic, Piezopolymer, Piezoquartz )
- Bending plateMeasurement based on strain gauges
(deformation)
Load cellDirect weight measurement
02_ Description
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
WIM Classification (Sensor technology): Piezoelectric Bending plate Load cell
02_ Description
Installation time:0,5 – 1 day
Installation time:2 days
Installation time:3+ days
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
WIM Classification (Sensor technology): 02_ Description
WIM Classification (Sensor technology):
Percent Error (at Highway Speed)
Estimated Initial cost per lane
Estimated Average cost per lane per Year
Piezoelectric Sensor ± 10% 18.000 € 5.800 €Bending-Plate Sensor ± 5% 30.000 € 6.300 €Piezoquartz sensor ± 5% 35.000 € 8.000 €Single Load Cell ± 3% 60.000 € 7.000 €
12
Source: NCHRP Report Nº 509
1.- Pavement rehabilitation not included
2.- Considering maintenance and annual calibration. Some of these systems are unlikely to reach a 12-year life. Piezoelectric / Piezoquartz sensors should probably be replaced after 4-6 years
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
03_ Application on enforcement strategies3.1_ Data collection 3.2_ High speed WIM as an screening tool for scales3.3_ Low speed WIM replacing static weigh stations3.4_ Permanent control on targeted places3.5_ Portable low speed WIM to improve roadside inspection3.6_ Other WIM applications3.7_ WIM Disadvantages
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
03_ Application on enforcement strategies3.1_Data collection
Have a general overview of the fleet on real traffic conditionsPlanning purposes as road capacity or pavement designIdentify vehicle groups with special load characteristicsCheck the influence of the new load enforcement measures
Data collection
Enforcement measures
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
03_ Application on enforcement strategies3.2_ High speed WIM as an screening tool for scales
As a screening tool for a weight enforcement facility in conjunction with a static or slow speed dynamic scale.
Benefits:Higher number of controlled vehicles
Increase the effectiveness of the main scale
Reduce burden on compliant drivers
Allows real circulation context inspection
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
03_ Application on enforcement strategies3.3_ Low speed WIM replacing static weigh stations
Low speed WIM (ASTM Type IV) can be accurate enough to replace the enforcement scale
Benefits:Increase the capacity of the scale
Reduce burden on compliant drivers (reducing queues)
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
03_ Application on enforcement strategies3.4_ Permanent control on targeted places
WIM allows a semi-automatic control of all vehicles on places were overloaded conditions can be foreseen
Benefits:Allows control of faster control of all vehicles
Reduce burden on compliant drivers (reducing queues)
Allows real circulation context inspectionMettler: www.mtwim.com
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
03_ Application on enforcement strategies3.5_ Portable low speed WIM to improve roadside inspection
Portable WIM systems can be used to generate improved roadside inspection.
Benefits:Not necessary to go to a static scale if the vehicle seems to be overweighed
Allows real circulation context inspection
Exhaustive and unexpected enforcement on specific zones
Effective measure to generalize the compliance
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
03_ Application on enforcement strategies
Bridge overweight applications3.6_ Other WIM Applications
Pavement control
Industrial applications
Transcale: www.transcale.com
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
03_ Application on enforcement strategies3.7_ WIM Disadvantages
Installation place requirements (ASTM E-1318-02)
Road geometry (straight and flat)
Road surface (smooth and resistant)
Installation costs
Maintenance & calibration costs
Fixed locations in most of the systems
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
04_ System ResultsThe WIM use has been reported by VOSA on several Efectiveness reports(2002/03, 2003/04), and on the annual report 2004/05. After several years of using the system they have the intention to extend its use as a way of roadworthiness enforcement.
After its implementation in Montana (project STARS) a significant drop (22%) of the overweight trucks circulating on the network of highways was noticed. Apart from the safety increase, this implied saving around $700,000 in pavement damage reparations.
The ITS (Intelligent Transportation System) performed a simulation to study truck congestion and to evaluate the use of weigh-in-motion (WIM) scales. The WIM was considered to be very effective at reducing the number of trucks required to be weighed at the static scale resulting in a significant reduction in average queue length, time spent in the queue, and queue overflow.
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
04_ System ResultsThe 'Green Light' project done in Oregon, (also from ITS), which include a WIM system, was evaluated on the following way:
Benefits include: reductions in road damage, reduced tax administration costs, improvements in truck safety inspections, less tax evasion, improved size and weight enforcement and improvements in productivity forcommercial carriers.
Estimated benefit/cost ratios over twenty years is 3.6 with an estimated internal rate of return of 40.5%.
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
05_ Conclusions
Overloaded vehicles represent a safety problem which is hardly affordable without real traffic data
WIM systems allow an inspection of the traffic of freight vehicles in a real context, where no avoidance of the system is possible (WIM integrated in the road)
WIM can be used as an enforcement tool on different ways:
High speed systems as screening tool for static (or low speed dynamic) scaleweigh stations
Low speed WIM systems replacing static weigh stations (increasing the number of controlled vehicles)
Low speed portable WIM systems allowing improvements on roadside inspection
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
05_ Conclusions
Near future WIM systems will be able to work following the scheme of speed radars (Virtual weigh station)
Additional benefits (as pavement protection) should be considered on the cost-benefit analysis
As a result, the flow of overweight trucks can be reduced significantly, ensuring an increase in the road safety
Víctor Salvachúa Barceló CITA Conference, Hanoi October 2006
Weigh In Motion Systems
Thank you very much for your attention
Víctor Salvachúa Barceló
Weigh In Motion Systems
Safety & Environment
Sustainability
Road Transport
In-service Vehicle Inspection
Agenda1- Opening
2- Speakers IntroductionMr. Mäurer from DEKRA, GermanyMr. Van Calker from FSD GmbH, GermanyMr. Viscido from CITA, BelgiumMr. Salvachua from Applus+, Spain
3- Questions & Answers
4- Summary and Conclusions
5- Closure
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM
‘‘The future of Vehicle Inspection The future of Vehicle Inspection –– Contributing to Sustainable Road Contributing to Sustainable Road TransportTransport’’
‘‘Developments in Inspection of 2 & 3 Wheeled VehiclesDevelopments in Inspection of 2 & 3 Wheeled Vehicles’’
2006 CITA CONFERENCE2006 CITA CONFERENCE
THANK THANK YOUYOU!!
Safety & Environment
Sustainability
Road Transport
In-service Vehicle Inspection
2006 CITA CONFERENCE, 17 – 20 October, Hanoi, VIETNAM