FORM 2
THE PATENT ACT, 1970,
(39 OF 1970)
&
THE PATENTS RULE, 2003
COMPLETE SPECIFICATION
(SEE SECTION 10; RULE 13)
"A SYSTEM FOR PRE-SETTING AN ENGINE MANAGEMENT SYSTEM CONTROLLER ON
ASSEMBLY LINE"
MAHINDRA & MAHINDRA LIMITED
A COMPANY REGISTERED UNDER THE PROVISIONS
OF COMPANIES ACT, 1956 HAVING ADDRESS AT,
R&D CENTER, AUTOMOTIVE SECTOR,
89, M.I.D.C, SATPUR, NASHIK - 422 007,
MAHARASHTRA, INDIA.
THE FOLLOWING SPECIFICATION DESCRIBES THE NATURE OF THE INVENTION AND
MANNER IN WHICH IT IS TO BE PERFORMED

FIELD OF THE INVENTION:-
The present invention is related to assembly methods in manufacturing industry. More particularly the present invention is related to pre-setting the controller (Electronic control unit) of an engine management system (EMS) on assembly line of the vehicle by creating virtual vehicle present and thereby reducing the vehicle assembly time and eliminating the error.
BACKGROUND OF THE INVENTION:-
A vehicle assembly shop in basically divided in three parts 1.Trims 2.Chassis and 3.Final
1. Trims - All interior wiring and interior components and aesthetic parts are fitted in trimming areas.
2. Chassis -All fitments required on chassis e.g. break tubes, tyres, fuel tank, exhaust etc are fitted o chassis line.
3. Final - Vehicle is made live on final line flashing activities, AC gas filling, Vehicle cranking etc is done here.
Now a day's vehicles come with various electronic features. For functioning of these features our vehicle has lot many sensors connected to it like Speed sensors, Brake sensors , Air bag sensors etc.
All these sensors take inputs from field give to the "Brain "of vehicle. The Brain takes decision and commands the vehicle to act accordingly.
Following are the essential controller
1. Engine Management System Controller.
2. Instrument Cluster controller.
3. Infotainment system controller.
4. AC Temperature controller
The following are optional contollers
1. Airbag Controller.
2. Anti-Brake System Controller.
3. Digital Information system Controller.

4. Rear Parking Assistant Controller
5. MBFM Special centralized controller to co-ordinate all controllers
6. Automatic transmission controller.
These controllers need to be flashed i.e. they need to be programmed according to the different vehicle features & configurations to make them live and ready to use for that particular vehicle.
During assembly of an automotive vehicle, different components of the vehicle are mounted in the vehicle. The different components are like engine, gear box, different ECUs, air bags, speed sensors, automatic braking system (ABS), wiring harnesses, etc. When all these components are mounted/fitted in the vehicle, the ECU that controls to all these components needs to be loaded with a set of pre-set operating parameters with respect to the vehicle model and/or variants. A set of pre-set operating parameters is available in the computer which is offline of the assembly line. Conventionally this loading of pre-set parameters is done by connecting the ECU of the EMS to the computer through wiring harness. But for this the vehicle in physical form with all the necessary components fitted therein is required.
Conventional method
Now As this vehicle comes with all controllers fitted and all connections done to it on Final line.
At final line as soon as battery connection is done we can flash the intended program into these ECUs.
Process Flow:-
Vehicle is moving on line, as vehicle arrives on intended stage a cable is connected through PC to the vehicle via a vehicle interface as shown in below figure.
There is a socket in vehicle through which the vehicle interface can communicate to all
controllers in vehicle.
This Socket is called as On board diagnostics socket (OBD)

So a cable goes from OBD socket to vehicle interface and then
Vehicle arrives on stage.



Vehicle number which defines its features in indicated on it through a barcode.

Barcode is scanned by the scanner.

This data is read by PC and intended program is selected from a database.

One by one all controllers are flashed in sequential manner.
The present invention is addressed to eliminate the physical requirement of the vehicle for loading a set of pre-set data parameters in the ECU of the EMS.
OBJECTIVES OF THE PRESENT INVENTION:-
The main object of the present invention is to provide a unique method of pre-setting an engine management system controller on assembly line.
Another object of the present invention is to provide a unique method of pre-setting an engine management system controller on assembly line and thereby reducing the assembly time / throughput time.
Yet, another object of the present invention is to provide a unique method of pre-setting an engine management system controller on assembly line that eliminates the error in the loading activities.

STATEMENT OF INVENTION:-
Accordingly invention provides a system for pre-setting an engine management system controller on assembly line comprises a circuit jig with external power supply means to controller with a ignition switch and relay system; one or more number sockets with connection to said power supply provided on the said circuit jig for connecting individual controller; a two wire controller area network provided to the said sockets for communication; a computer, having data base of various pre-setting programmes for controller, connected to the said circuit jig through the said controller area net work; an On board diagnostics socket (OBD) provided for cable connecting to vehicle interface; a bar code scanner provided to the said circuit jig communicating to the said computer for identifying vehicle to select preset programme flashing.
BRIEF DESCRIPTION OF THE FIGURES:-
The above mentioned objectives and the advantages derived out of the present invention will
be better understood through the following specifications when read in conjunction with
following figures, wherein
Figure 1 shows the block diagram of the system of pre-setting an engine management system
controller in accordance with the present invention.
Figure 1 A shows plan view of circuit jig according to invention
Figure 2 shows block diagram various essential and optional controller in the vehicles.
Figure 3 shows circuit jig with wiring and sockets for controller and connecting vehicle
interface to access installed controllers in the vehicle.
Figure 4 shows conventional system for flashing.
Figure 5 shows schematic diagram showing the controllers in the vehicle.
DETAILED DESCRIPTION OF THE PRESENT INVENTION:-

The present invention focus on providing solutions for easy assembly process to eliminate bottle necks on manufacturing line and reduce through put time.
A circuit of jig as per figure 1
A used in the system with following features:
All controllers communicate through a protocol called CAN ( Controller Area Network)
This communication is basically a circuit with double wire network between controllers.
The circuit is developed in this jig.
This covers communication part of vehicle.
Jig is connected externally with a power supply which does the job of battery in vehicle.
A switch is provided on jig which does the job of ignition in vehicle.
Teflon sockets are installed on the jigs for connecting various controllers.
This completes the entire vehicle environment in a single jig.
The jig is made such that different types of ECUs can be flashed on the same jig.
As shown in figure 3
Block A, B & C is sockets to insert controllers
Block D is ignition switch
Block E is OBD connector to connect vehicle interface
All these are connected to each other through 4 essential wires Viz.
1. Red wire - This carries 12 v supply to all the components on the jig
2. Black wire - This is the negative wire which is required to complete the circuit.
3. Green Wire - This is communication cable called CAN LOW
4. Yellow Wire - This is communication cable called CAN HIGH
CAN high and CAN low cables are used for bits transfer from ECUs to OBD connector i.e. Block E
This OBD connector then communicates further to Vehicle Communication Interface.
To start the process of Flashing we need to start the power supply. On switching on the ignition, Controller is ready to transmit and receive the data.

Once controllers are inserted on jig and ignition is on then a barcode is scanned. This scanned data goes to the PC using a scanner. PC selects a specific program from data base and flashes this program in all ECUs simultaneously.
A indication is given on screen when all controllers are flashed.
Thus the process of offline flashing is complete.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The present disclosure envisages vehicle ECU flashing process on manufacturing line to de bottle neck the line and increase capacity with lower through put time.
The system of the invention comprises of master controller, unique jig, communication means from jigs to master controller, human interface to command the master controller, activity completion signalling means, etc. The master controller stores data files for vehicle based

data which ware logically selected and transfer to vehicle ECU of the engine management system through communication means. Arrangement for the activity is made out of vehicle by creating vehicle environment by communication lines. This arrangement consists of JIG with sockets and circuitry for enabling the process to happen without presence of respective vehicle. Jig is an unique hardware with sockets for connectivity with different means and is capable and/configured to substitute the vehicle in physical form during the data transfer operation. Communication means with vehicle ECU is connected to master controller which then allows the master controller to transfer the desired set of parameters to the engine ECU.
The data, for example injector quantity adjustment, which is generally in multiple digits, specifically more than six digits, for each injector is to be is to be loaded in the engine ECU which need physical engine to be present in vehicle while flashing as it is fetched from Engine from sticker is attached to Engine. To ensure the data transfer in Vehicle ECU data is captured from the engine barcode and transferred to Vehicle ECU virtually by Ethernet cable by creating a server to maintain data as per vehicle sequence and provide when vehicle computer is being programmed.
The process in accordance with the present disclosure has several technical advantages including but not limited to the realization of:
- It is very simple method for vehicle ECU loading without need of physical vehicle presence during the operation.
- This system helps to test the vehicle ECU and data set for their compatibility anywhere away from vehicle.
- The jig mentioned in the specification is a configured with unique features that eliminates the need of physical vehicle during the operation of data loading from master controller to engine ECU.
- The system allows the operation of data loading in engine ECU before complete assembly of the vehicle.
- No dependability of the other processes on this process as the process is altogether disconnected from main assembly process.
- Further, the system comprises a feature wherein the user can set the sequence of data loading from master controller to engine ECU through the user interface means provided with master controller therefore.

- The system permits the data loading activity even before the assembly of engine with the chassis / vehicle.
- This method reduces the throughput time by 20% that thereby contributes to the increment in the production output.
- The method also eliminates the involvement of human operator thereby reducing the human power requirement during the operation.

WE CLAIM:-
1. A system for pre-setting an engine management system controller on assembly line comprises a circuit jig with external power supply means to controller with a ignition switch and relay system; one or more number sockets with connection to said power supply provided on the said circuit jig for connecting individual controller; a two wire controller area network provided to the said sockets for communication; a computer, having data base of various pre-setting programmes for controller, connected to the said circuit jig through the said controller area net work; an On board diagnostics socket (OBD) provided for cable connecting to vehicle interface; a bar code scanner provided to the said circuit jig communicating to the said computer for identifying vehicle to select preset programme flashing.