DE102012207342A1 - Error analyzing device of error analysis system for determining causes of errors in successive process for assembling and operation of e.g. truck, has interface that is communication with movement system to detect vehicle system time - Google Patents

Abstract

The error analyzing device has a fault memory and an interface that are communicated with a vehicle system of a vehicle to detect errors on the vehicle via the interface and store the error data in the fault memory. Another interface is communication with a movement system to detect a vehicle system time of the vehicle and to store the error data indicating the vehicle system time at which the error is occurred. An independent claim is included for method for determining causes of errors.

Description

The present invention relates to vehicle assembly and / or commissioning processes, in particular a device for error analysis in connection with a quality inspection in a vehicle. Furthermore, the invention relates to a method for analyzing errors and determining causes of errors when commissioning a vehicle.

In the production of vehicles, eg. As passenger cars or trucks, the quality of the vehicles can be increased if errors in the production process can be assigned to a specific cause of failure. A production process includes the installation and commissioning of each individual components, with the commissioning, z. B. of window regulators, with the assembly of z. As a seat or interior trim, overlap in time. The errors can affect the vehicle itself or the commissioning process. The number of possible errors is immense, depending on the vehicle type in the four- or five-digit range. All in all, a high number of errors can accumulate, which can well be in the range of 200 to 300 errors. In principle, the errors can be detected by individual control units, which can identify detected errors in each case via up to 1500 error codes. But the error code itself does not say anything about a cause of the error, because a certain error may have been caused by a variety of causes.

To realize the most meaningful error detection errors are usually on statuses, check routines or other quality assurance measures, such. As entries in error memory of ECUs, noted, in particular in each case in connection with the commissioning of individual components of the vehicles and at the end once globally after completion of the entire production process.

It is therefore difficult not only to detect a specific error, but also to attribute it to a cause of error. It is therefore usually not easy to improve the production or the commissioning process, that is, to carry out less error-prone work. The difficulty of determining a cause of error is also compounded by the fact that certain errors can have different causes, and in one case, for example. B. due to a first cause of error, in another case, but due to a second cause of the error. It can not be clearly distinguished between random errors and errors that occur regularly in certain process steps. Therefore, the error alone can only supply insufficient information to be able to determine and eliminate a cause of the error.

The publication DE 10 2005 037 913 A1 shows a method for error documentation in a motor vehicle with a plurality of control units, which are respectively designed for the detection and reporting of errors, wherein an association of vehicle condition data is made possible for an error description.

The publication DE 10 2005 019 062 B3 shows a test method in connection with the commissioning of a motor vehicle, in which wheel speed sensors are tested and in a detected error of the wheel speed sensors, the vehicle can be controlled by it is shut down.

The object of the invention is to at least partially overcome the disadvantages described above in a production process of a vehicle. In particular, it is the task to enable a precise localization of causes of errors in a vehicle production process and thus a high-quality production process or a reliable commissioning process of a vehicle. The causes of the errors can be on the one hand in the vehicle, for example due to a faulty component, or on the other hand in the production process, for example due to a wrong procedure in the production process. It is also the object to provide an apparatus or a method for error analysis, by means of which error causes can be determined with good accuracy. Last but not least, it is the task to provide a system by means of which a quick or clear assignment of errors to causes of errors is possible.

At least one of the above objects is achieved by a fault analysis device having the features of claim 1 and by a method for determining causes of faults having the features according to claim 8. Further features and details of the invention emerge from the subclaims, the description and the drawings. In this case, features and details that are described in connection with the error analysis device according to the invention, also in connection with the inventive method and in each case vice versa, so that with respect to the disclosure of the individual aspects of the invention always reciprocal reference can be made.

According to the first aspect of the invention, the object is achieved by an error analysis device for determining causes of errors in a plurality of successive process steps for assembly and / or commissioning of a vehicle, wherein the error analysis device has a fault memory and an interface for communication with a vehicle system of a vehicle and is adapted to capture error data relating to errors on the vehicle via the interface and stored in the error memory, solved which the error analysis device for communication with a plant system is designed to detect a vehicle system time of the vehicle via the interface and to store the error data stating the vehicle system time at which a respective error has occurred and to correlate these with specific process steps via the plant system.

The fault analysis device may perform an error analysis based on the vehicle system time. The error analysis may be performed by the failure analysis device entering into communication with the plant system in order to obtain from the plant system detailed information about the individual process steps performed on a respective vehicle. The error analysis device is basically designed as an independent component, which is independent of a plant system and communicates between the plant system and a vehicle system. However, by transmitting the vehicle system time and error data to a plant system, the failure analysis apparatus may also enable the plant system to perform an error analysis. Depending on the application, it may also be advantageous if the error analysis device is designed as part or component of a plant system.

This allows localization of a cause of the error. A Failure Mode and Effects Analysis (FMEA) can be more meaningful. Furthermore, it is possible to correlate with the relevant step causing the error or commissioning process step over the vehicle system time, because the errors can be analyzed with reference to the time at which they occurred. It can be determined exactly at what time and thereby also at which point in the process, ie. H. at which machine or which process step a certain error has occurred, in particular also in the case of several steps executed successively by a machine. This is particularly advantageous in connection with series startups, in which errors can occur more frequently in the commissioning process and there is hardly any information about the weaknesses and the susceptibility to error in individual process steps, be it the fault in the vehicle or in the process step itself.

The error data is preferably an error number to understand, or a yes-no statement whether an error exists or not.

As a result, a cause of the error can also be determined more accurately than if an error memory is only read out by control units at specific times without further information about the occurrence of an error. Although it is possible to repeatedly read a fault memory of control devices in short time intervals and to compare the read values with each other to then assign the latest error messages or last collected error data time to a specific production or commissioning process step. However, this procedure remains inaccurate and also requires process time or continuous data processing.

The error analysis device may each have a specific interface for communication with the vehicle system and for communication with the plant system, in particular a first interface for communication with the vehicle system and a second interface for communication with the plant system. The communication can be done independently, z. Also by using a specific communication standard.

The first and second interfaces can be of different types. These may be divergent data transmission methods, e.g. B. to preclude interference during data transmission. However, it is also possible to provide the same type of data transmission, but the two interfaces are then preferably designed independently of each other. Optionally, the two interfaces can also be designed as a combined interface, in which the data transmission takes place successively in time successively, ie sequentially only between the factory system and the error analysis device and then between the plant system and the vehicle or vice versa.

As a plant system is preferably a monitoring or control system in connection with an at least partially automated production and / or commissioning process, especially in vehicles to understand. In a plant system, all or at least a majority of the processes executed are in some way controlled, controlled or at least tracked and logged.

As a detection of error data is to be understood preferably both a passive feeding and an active reading of error data in the error analysis device. It can also read out or discharge of error data from the error analysis device via the interface.

According to a preferred development of the invention, the error analysis device is designed to record a factory time of the plant system and to correlate the error data with the corresponding vehicle system times with the factory time.

The specific factory time can z. B. in the form of a timestamp for each production step or commissioning step are retained, in particular by the plant system itself, which may be adapted to deposit the timestamps together with an identifier for each step in the process step list. The factory time and the vehicle system time thus serve as a link between the errors and individual process steps. It has been shown that due to the high volume of data and information about individual process steps and production processes and vehicle types (production lines) it is not possible to store the entire data in a vehicle system. Due to the inventive design of the error analysis device or the plant system can be done by a small amount of data or a fast data exchange via standard communication interfaces, a link between errors and process steps, and the analysis of error causes is more meaningful. In particular, the data transmission in any case occurring in connection with the error messages only requires setting a time stamp of the vehicle system with a time stamp from the plant system in relation to one another and, based on this temporal relationship in the database for the individual process steps over time, assigning Error times to make process steps.

According to a variant, the error analysis device may also have a time clock and be designed for a timed communication with the plant system. It can be designed to record the vehicle system time at a specific factory time of the plant system and to correlate the vehicle system time with the specific factory time. As a result, a plant system can resort to new information determined at short notice at certain points in time and perform an error analysis on a current data basis.

As a clocked or periodic communication is preferably a communication to be understood, in which a data transmission takes place at certain times or at certain time intervals according to a predefined flowchart. This can be done at always the same time intervals, but it can also be done at certain (for the quality or accuracy) particularly relevant times or process steps.

Optionally, the failure analysis device may also be in continuous, d. H. be continuous communication with the plant system and transfer error data or even general data on the process progress to the plant system or receive general data from the plant system.

According to a preferred further development of the invention, the error analysis device is designed to correlate the error data with the factory time and with a specific process step which is related to the particular factory time, wherein for each process step a factory time to which the process step was performed is assigned in a process step list is, and the error analysis device is adapted to access the process step list via the interface.

Optionally, the fault analysis device may load the process step list once and take it into account in the further communication without having to repeatedly access it via the second interface. This is useful if the process steps are processed without deviation according to a standard procedure.

According to a preferred development of the invention, the fault analysis device is embodied as a control device or at least as part of a control device, which has a first interface for communication with the vehicle system and a second interface for communication with the plant system, and which is designed to the second interface to transmit error data actively to the factory system at the time of occurrence of the respective error. An active transmission is also possible if the communication takes place solely via an interface.

According to a preferred development of the invention, the fault analysis device has an interface which is designed to store environmental data detected by an environmental sensor in the fault memory. The interface for the collection of environmental data may be a separate interface, so that the control unit is designed with three interfaces. The environmental data can also be transmitted via an existing interface, depending on the communication standard of the environmental sensors.

The error analysis device can also be designed to detect even vehicle data, in particular via the first interface, or from a vehicle, and to correlate the environmental data with the vehicle data. Optionally, the fault analysis device may include the environmental sensor (s) itself.

In addition to the error analysis device according to the invention, the task of correlation can also be assumed by a plant system according to the invention for determining causes of errors in a plurality of successive process steps for assembling and / or commissioning a vehicle, wherein the plant system has an interface for communication with a vehicle system or a fault analysis device according to the invention and wherein the plant system has means for detecting a factory time and is adapted to detect a vehicle system time via the interface and to correlate the factory time with the vehicle system time.

• – Erfassen von Fehlerdaten zu aufgetretenen Fehlern und Hinterlegen der Fehlerdaten in einem Fehlerspeicher unter Angabe einer Fahrzeugsystemzeit, zu welcher ein jeweiliger Fehler aufgetreten ist;
• – Auslesen der Fahrzeugsystemzeit;
• – Übermitteln der Fahrzeugsystemzeit an eine Fehleranalysevorrichtung oder ein Werkssystem;
• – Korrelieren der Fehlerdaten über die Fahrzeugsystemzeit mit bestimmten Prozessschritten.

As already mentioned, at least one of the above objects is also achieved by a method for determining causes of errors in a plurality of successive process steps for assembling and / or commissioning a vehicle having the features according to claim 8, wherein the method is characterized by the following method steps:

• - detecting error data on errors that have occurred and storing the error data in an error memory indicating a vehicle system time at which a respective error has occurred;
• - read the vehicle system time;
• Transmitting the vehicle system time to a fault analysis device or a plant system;
• - Correlating the error data on the vehicle system time with certain process steps.

Since a time stamp is generated for individual or all process steps in the factory process and the vehicle system time is read out at certain time intervals, the production or commissioning process can be monitored more accurately. A correlation of factory and vehicle system time leads to an error analysis, in which each error over the temporal information can be assigned a cause of error.

The method according to the invention can be carried out solely by a fault analysis device which is in communication with a vehicle system and a plant system. The step of correlating the error data with a specific process step leads to the knowledge in which process step which error occurs.

A process step in this case is preferably a sub-process in the production or commissioning of a single vehicle. The vehicle system time may be provided by a vehicle system, particularly one of many vehicle systems. For this purpose, the vehicle system may have means for detecting the vehicle system time. The fault memory may be provided by the vehicle itself or by a fault analysis device according to the invention.

According to a preferred development of the invention, it can be provided in the method that the correlation of the error data with specific process steps takes place over a factory time of the plant system, the factory time being predetermined by the plant system.

This allows a retroactive or future correlation for all other error messages, since a specific factory time for all other error times of a belonging to an error vehicle system time can be assigned.

The factory time can be specified by a plant system. To correlate the vehicle system time with the factory time, transmission of the vehicle system time to the plant system can take place. By specifying the vehicle system time for each occurring error, it is possible to subsequently correlate each error with a factory time, including an error that has occurred before or after the step of reading the vehicle system time from the vehicle to a specific plant time of a plant system. The individual process steps are identified by the plant system by a respective factory time. This can be a standard factory time, which is inherent to a process step, so z. For example, every Monday morning at 7:13, and 47 seconds, a process step starts the engine, or it may be a specific factory time at which a particular process step is performed only unscheduled or irregular. Then the corresponding process step is stored separately with the specific plant time in a plant system.

The read-out of the vehicle system time and possibly also of error data can be carried out as a function of specific time patterns, in particular iteratively at certain times of the works, in particular factory times, at which specific commissioning steps take place. For this purpose, the error analysis device may have a clock generator which causes the error analysis device to enter into communication with the plant system at specific time intervals. Alternatively, the read-out of the vehicle system time and possibly also of fault data depending on specific process steps of commissioning or testing done.

The read-out of the vehicle system time can also take place at a specific factory time of the plant system, in particular also at defined time intervals or with reference to specific times or events during production.

• – Aufzeichnen und Hinterlegen von Prozessdaten zu am jeweiligen Fahrzeug ausgeführten Prozessschritten unter Angabe der bestimmten Werkszeit für jeden bestimmten Prozessschritt;
• – Auslesen der Fehlerdaten und Fahrzeugsystemzeiten aus dem Fehlerspeicher; wobei es für alle Fahrzeuge gemeinsam den folgenden Schritt umfasst:
• – Generieren einer Fehlerliste auf Grundlage der Fehlerdaten, Fahrzeugsystemzeiten und Prozessdaten, in welcher jeder Fehler durch seine Häufigkeit und den Prozessschritt, in welchem er auftritt, gekennzeichnet ist.

According to a preferred development of the invention, the method may be provided for being carried out for a plurality of vehicles and for each vehicle comprising the following steps:

• Recording and storing process data on process steps carried out on the respective vehicle, specifying the specific factory time for each particular process step;
• - Reading the error data and vehicle system times from the error memory; wherein it includes for all vehicles together the following step:
• Generating a fault list based on the fault data, vehicle system times and process data, in which each fault is characterized by its frequency and the process step in which it occurs.

As a result, statistics can be created in which the causes of the errors can be evaluated via a large number of vehicles, and an assignment to specific process steps can be made even more clearly. Individual errors can be assigned with a high degree of certainty to a specific time of occurrence and it can also be differentiated more precisely between individual subtasks in a process step. If the error z. B. always after about two seconds in a five-second welding process, so z. For example, it is possible to investigate whether the cause of the fault lies in the fact that the welding tool is not guided at the correct speed or at the correct distance from the workpiece in the second second.

In addition, the optional equipment of the vehicles, in particular those that cause electronic or mechanical differences in the vehicles, can be added to the list of defects. This makes it possible for all vehicles to jointly check faults to see if they only occur in the case of certain optional extras of the vehicle. These error quantities can then be further cut with the other error lists mentioned.

In addition, the version of the vehicle parts or of the entire vehicle can be stored in order to set errors also with respect to newer and older versions of the control units, the control unit software or the entire vehicle. These error quantities can then be further cut with the other error lists mentioned.

In addition, the process data may contain information on what date the process step was performed, which version the process step has and whether the process step was completed successfully or with a certain process step error or which return value the process step provided.

The error list can optionally be filtered, in particular in order to evaluate the list statistically with regard to specific questions or data bases. Optionally, a filtered error list can be output. The process step of recording and depositing process data can be carried out by the plant system, which can then also transmit the process data to the error analysis device for further evaluation. However, it can also be carried out by the error analysis device itself, in that the error analysis device gains access to process data stored in the plant system via the interface or one of the interfaces.

The method step of reading out the error data and vehicle system times can also preferably be carried out by the plant system. The method steps of generating an error list and the optionally additionally performed method step of filtering the error list and optionally outputting a filtered error list can also preferably be carried out by the plant system. For this purpose, the plant system may have an error data evaluation unit, which is designed to evaluate the collected data and z. For example, you can specify a statistical distribution of error frequencies and a probability for specific error causes. The error data evaluation unit may be in communication with display means for displaying the error list or other information. The plant system may further include a filter for filtering the defect list or in communication with a filter. Optionally, the error analysis device can also carry out the method steps carried out jointly for all vehicles and for this purpose have an error data evaluation unit and display means and be in connection with a filter or have the filter itself.

• – ein Filter, der eine Liste von Fehlern, deren Fehlerursache inzwischen geklärt werden konnte, aus der Gesamtbetrachtung ausblendet,
• – ein Filter, der nur diejenigen Fehler anzeigt, die sich besonders signifikant an einzelnen Prozessschritten häufen, also alle Fehler ausblendet, die nur selten beziehungsweise verstreut über den Produktionsprozess auftreten,
• – ein Filter, der einem Prozessschrittverantwortlichen ermöglicht, nur diejenigen Fehler zu sehen, die an seinem Prozessschritt auftreten (beispielsweise nach Top-Fehlern absteigend sortiert),
• – ein Filter, der nur diejenigen Fehler anzeigt, die signifikant für eine bestimmte Serienausstattung des Fahrzeugs sind,
• – ein Filter, der nur diejenigen Fehler anzeigt, die seit einer bestimmten Version von Steuergeräten oder Fahrzeugen hinzugekommen sind,
• – ein Filter, der es ermöglicht zu sehen, ob ein bestimmter Fehlercode signifikant für eine Version, eine Sonderausstattung oder einen Prozessschritt ist,
• – ein Filter, der ab einem bestimmten Datum, insbesondere einem Datum einer Produktionsprozess-Änderung, die ab dann signifikant gehäuften oder ab dann signifikant reduzierten Fehlercodes anzeigt,
• – ein Filter der es ermöglicht, nur die Fehler eines bestimmten Fahrzeugs (Fahrgestellnummer) oder einer Liste von Fahrgestellnummern anzuzeigen,
• – ein Filter, der Fehler nur dann anzeigt, wenn eine bestimmte Umweltbedingung oder eine bestimmte Kombination von Umweltbedingungen zum Fehlerzeitpunkt vorgelegen hat oder nicht vorgelegen hat,
• – ein Filter, die nur die häufigsten, die sogenannten TOP-Fehler, anzeigt,
• – ein Filter, der diejenigen Fehler ausblendet, die zum gleichen Zeitpunkt aufgetreten sind, wie bestimmte im Werks-Produktionssystem erkannte Fehlerzustände (Beispiel: Produktionssystem hat mechanischen defekt eines Teils festgestellt. Diese Fehlerursache soll somit nicht mitbetrachtet werden), oder
• – ein Filter, der die Kombination zweier oder mehrerer oben genannter Filter ermöglicht.

As a filtered list of errors is preferred to consider a list of errors, which lists only errors that can be attributed significantly to a particular process step. The filtering step can be done optionally and, depending on the filter, also in relation to specific questions in the Analysis of causes of errors. If one considers a statistically relevant amount of vehicles, for example several thousand vehicles, in absolute terms very many errors occur that can hardly be surveyed without suitable filtering. Especially useful filters are:

• A filter which excludes from the overall view a list of errors whose cause of error could now be clarified,
• A filter which only displays those errors which accumulate particularly significantly at individual process steps, ie hide all errors that occur only rarely or scattered throughout the production process,
• A filter that allows a process step manager to see only those errors that occur in his process step (for example, sorted descendingly after top errors),
• A filter which only displays those errors which are significant for a particular standard equipment of the vehicle,
• A filter that only displays those errors that have been added since a certain version of ECUs or vehicles,
• A filter that allows you to see if a particular error code is significant for a version, an option or a process step,
• A filter which, starting from a specific date, in particular a date of a production process change, displays the then significantly increased or then significantly reduced error codes,
• A filter which allows to display only the faults of a particular vehicle (chassis number) or a list of chassis numbers,
• A filter that only displays errors if there was or was not a specific environmental condition or combination of environmental conditions at the time of the error,
• A filter that displays only the most common, the so-called TOP errors,
• - a filter that fades out errors that occurred at the same time as certain fault conditions detected in the factory production system (example: production system has detected mechanical defect of a part, so this cause should not be considered), or
• - A filter that allows the combination of two or more of the above filters.

According to a preferred further development of the invention, the method may provide that the determination of causes of faults is carried out on an extended basis by correlating environmental data with vehicle data and taking them into account in order to determine the cause of the fault as a function of the environmental data.

As a result, not only can it be determined for a large number of vehicles when and where, but also under which boundary conditions certain errors occur. Thus, the determination of the cause of the error can be made more accurate. In particular, for a lot of z. B. x = 100 vehicles a specific error, which has indeed occurred in only one particular commissioning step, but not in all vehicles, thereby a cause of failure are assigned, that in all vehicles, the environmental conditions and environmental data are collected and compared. The environmental data can z. B. are collected by a controller or by independent sensors, which are in connection with a fault memory and are designed to write their measurements, indicating the vehicle system time in the error memory. The environmental data can be further recorded by an in-vehicle or external data logger in parallel to the entire production process and also include the vehicle system time. The environmental data can z. B. concern a voltage measured by a controller, can be determined by their value, whether a vehicle was connected to the relevant commissioning step to an external power supply of the factory. The vehicle data can z. B. type of vehicle, engine type, or the type of specific equipment or devices in the vehicle concern which z. B. available as an optional extra only for individual vehicles. This makes it possible to refer certain errors also to individual vehicle types or the interaction of different components in the vehicle.

According to a preferred further development of the invention, it may be provided in the method that the step of detecting and storing the error data is performed by an error analysis device in the form of a control device which actively transmits the error data to the plant system at the time of occurrence of the respective error.

In this way, a correlation can be made by the plant system, in particular continuously, without a retroactive subsequent correlation of old error data is required. By means of active error messages or error data transmitted or transmitted in real time, errors and error causes can be determined even faster and suitable measures for better quality can be made faster. Optionally, an active transmission can also be made to a processor-controlled memory unit, ie a data logger, which is connected to the factory system. In particular, further recorded by the data logger continuous data records of the vehicle buses with the active transmissions of the error data directly correlated in time so that the recorded data can be correlated with the time of error and thus also with the process step. This characteristic has the additional advantage that a readout of the error data from the vehicle by the plant system is eliminated and thus laborious process time can be saved in the production process. The time saving of the active transmission of the faults by the vehicle compared to the reading of the faults by the factory system is explained by the fact that when reading through the factory system all control units must be asked successively for errors, even if it turns out that they had entered no errors, and that the control units then transmit all errors that are entered in each case, and not just the respectively acutely new error. This time savings can be significant in the production process.

Regardless of whether an error analysis by an inventive error analysis device or a plant system according to the invention, at least one of the above objects can also be solved by an error analysis system with an inventive error analysis device and / or a plant system according to the invention, in which the error analysis device comprises means for detecting a vehicle system time and the plant system has means for detecting a factory time, and the error analysis device or the plant system is adapted to associate a respective process step for assembling or commissioning vehicles with the factory time at which the process step takes place and a vehicle system time at which a respective error has occurred with specific process steps to correlate.

An error analysis device according to the invention and an inventive plant system and a method according to the invention are explained in more detail below with reference to drawings. Each show schematically:

1 a flowchart for a method and method steps based thereon according to an embodiment of the invention;

2 a schematic representation of the components that can be used according to an embodiment of the invention to enable a precise error analysis;

3 a schematic representation of the interfaces and communication paths over which an accurate error analysis can be made possible according to an embodiment of the invention; and

4 a timeline to illustrate the relationship between factory time and vehicle system time.

Elements with the same function and mode of action are in the 1 to 4 each provided with the same reference numerals.

In 1 are schematically individual process steps 1 . 1a . 2 . 3 . 4 . 5 . 6 . 7 and 8th related to each other, wherein the method step 1a optionally additionally between the method step 1 and 2 can be performed, and wherein the method steps 1 to 4 can be repeated in a loop with x repetitions, and with the method steps 1 to 6 repeatedly in a loop with x repetitions can be performed, with x equal to the amount of vehicles or a batch size, which can be used to determine a cause of failure. The detailed description of the individual method steps is apparent from the list of reference numerals.

After the process steps 4 . 6 . 7 and 8th may be an output of data to an error data evaluation unit 16 ; 36 take place, which can be provided either in a fault analysis device or a plant system. Between the procedural steps 4 and 5 is an arrow deviating from the other arrows indicated to emphasize that the process steps 1 to 4 already sufficient to determine a cause of error more precisely, depending on which form of data or database in the plant system can be used. In particular, the plant system can be designed so that it is already known for each process step to which vehicle system time it is at all feasible. It can be z. B. may be a one-time process that can only be performed at a particular vehicle system time. It may therefore not be necessary in exceptional cases to make an accurate error assignment via the detour of the factory time and a correlation of vehicle system time and factory time. The basic requirement, however, is the knowledge of the vehicle system time as well as a reference to a data basis about the process steps. This data base is preferably stored alone in the plant system, in particular for reasons of data volume.

Between the procedural steps 6 and 7 is a bracket hinted to highlight that the steps 7 and 8th on the basis of the data obtained in the previous procedural steps. In the process steps 6 and 7 it is about a statistical evaluation of the data collected by the iterations x.

In 2 are schematically a plant system 30 , an error analysis device 10 as well as several vehicle systems 20 showing one of the vehicle systems 20 in communication with the fault analysis device 10 or the plant system 30 is. The error analysis device 10 has a fault memory 11 , a first interface 12 , a second interface 13 , a third interface 14 , a clock 15 and optionally also an error data evaluation unit 16 and display means 17 on. About the first interface 12 can communicate with the vehicle system 20 via the second interface 13 can communicate with the plant system 30 done, and via the third interface 14 can communicate with an environmental sensor 50 done, which itself an interface 51 and which environmental data you record and optionally deposited. The error analysis device 10 can generate or access an error list Lf in which error data Df are stored, and it can be used in conjunction with a filter 40 to filter error data or this filter 40 exhibit. The filter 40 is from the error analysis device 10 or the factory system 30 used to create a filtered Lff error list.

The respective vehicle system 20 is shown schematically as a vehicle and has funds 21 for detecting a vehicle system time, a vehicle system interface 22 , an in-vehicle fault memory 23 and optionally also a clock 25 on, wherein the in-vehicle fault memory 23 from the error analysis device 10 can be read out. In the vehicle system 20 vehicle-specific vehicle data Dv can be stored.

The factory system 30 is shown schematically as a workshop and can be considered as an overall system in which both the vehicle systems 20 as well as the error analysis device 10 although the latter may be completely independent of him. It has funds 31 for detecting a factory time, optionally a timer, and an error data evaluation unit 36 and display means 37 , and is designed to interface 33 with the error analysis device 10 and to communicate directly with the vehicle system. The factory system 30 can on the filter 40 access or with the filter 40 work and can also access the error list Lf, be it via the error analysis device 10 or directly, with the error list Lf also from the factory system 30 can be generated. In the factory system 30 are stored process data, in particular in the form of a process step list Lp, in which process data Dp are stored. Optionally, the process step list Lp can be independent of the plant system 30 be stored, and then the factory system 30 which access the process step list Lp. The entire in 2 The arrangement shown can be used as a fault analysis system 60 be designated.

In 3 Shown schematically are interfaces and communication paths over which the error analysis device 10 , the factory system 30 and the vehicle system 20 each in communication with each other. The error analysis device 10 can also be an "offline system", only according to the file situation of the factory system 30 , for example, works in a database collected data (process steps, error data) works and thus subsequently and not only "live" can analyze the data.

Typically, only the factory system communicates 30 with the vehicle. The error analysis device 10 works preferably on the basis of the data that the plant system 30 has collected.

In addition, a data logger can be installed, which "virtually" into the connection between the factory system 30 and the error analysis device 10 is looped. However, this usually has no analysis logic and gives its data to the plant system 30 for storage in the database and thus for utilization by the error analysis device 10 from. The error analysis device 10 could thus be in 3 "Left" from the factory system 30 to be painted.

In the 4 schematically shows how a conclusion of a factory time Tw and a vehicle system time Tf can be made to individual detected errors F1, F2, ..., Fn, wherein the individual detected errors F1, F2, ..., Fn after a correlation at the time Tw0 individual process steps over the corresponding specific factory times Tw1, Tw2, ..., Twn to which a process step is performed, here specifically the error F1 over the factory time Tw3 the process step Ptw3 and F2 via Tw5 the process step Ptw5. The vehicle system time Tf can start to run at a start time Tf0, which is independent of a specific factory time Tw. The start time Tf0 can z. B. coincide with the beginning of a production process for the respective vehicle. The process step list Lp can be used to determine for the factory system or the error analysis device which steps are taken at a particular vehicle system time Tf, and the process step list Lp can be used to determine how the actual process steps are related to the standard steps , z. B. depending on a stoppage of the production line in connection with a strike, or a power outage, or a holiday.

It may occur in the vehicle production process that the vehicle system time does not progress as expected due to power interruptions or replacement of components of the vehicle that dictate the vehicle system time. Example: The control unit specifying the vehicle system time is replaced. For example, the system time restarts at an earlier value. In this case, without correcting the time correlation with the factory time error times would be assigned incorrectly.

• 1.) Die Zeitverschiebung automatisiert zu bemerken. Dies kann geschehen, indem an mindestens zwei Punkten, beispielsweise ganz zu Beginn und ganz am Ende des Werksprozesses, jeweils eine Korrelation zwischen Fahrzeugsystemzeit und Werkszeit durchgeführt wird und geprüft wird, ob der Betrag des Zeitfortschritts der Werkssystemzeit in Sekunden von Anfang bis Ende des Werksprozesses mit dem Betrag des Zeitfortschritts der Fahrzeugsystemzeit übereinstimmt. Falls hier eine Abweichung festgestellt wird, die über die Uhrengenauigkeit hinausgeht, dann muss eine Abweichung in der Systemzeit stattgefunden haben.
• 2.) Die Zeitverschiebung möglichst genau ab dem Zeitpunkt der Verschiebung wieder zu korrigieren. Nachdem die Zeitverschiebung erkannt wurde, ist es nun wichtig die Verschiebung zu korrigieren, um weiterhin zuverlässig Fehlerzeitpunkte zuordnen zu können. Eine gute Möglichkeit dazu ist, in regelmäßigen zeitlichen Abständen oder zu Beginn und Ende eines logisch zusammenhängenden Prüfablaufs jeweils eine Korrelation dadurch durchzuführen, dass die Systemzeit des Fahrzeugs ausgelesen und mit der Werkssystemzeit verglichen wird. Somit ist höchstens der Zeitraum zwischen zwei Zeitkorrelationszeitpunkten für eine Fehlerkorrelation verloren, falls in diesem Zeitraum eine Zeitverschiebung stattgefunden hat.

It is therefore necessary for such cases

• 1.) The time shift automated to notice. This can be done by at least two points, for example, at the very beginning and at the very end of the factory process, a correlation between vehicle system time and factory time is performed and checked whether the amount of time progress of the plant system time in seconds from the beginning to the end of the factory process with coincides with the amount of time progress of the vehicle system time. If a deviation is found here that goes beyond the clock accuracy, then a deviation in the system time must have taken place.
• 2.) To correct the time shift as accurately as possible from the time of the shift again. After the time difference has been detected, it is now important to correct the shift in order to be able to reliably allocate error times. A good way of doing this is to carry out a correlation at regular time intervals or at the beginning and end of a logically connected test sequence in that the system time of the vehicle is read out and compared with the plant system time. Thus, at most the time between two time correlation times for an error correlation is lost if there has been a time shift in that time period.

LIST OF REFERENCE NUMBERS

1

Process step of detecting and storing error data

1a

Method step of determining causes of failure on an extended basis by correlating environmental data with vehicle data

2

Method step of reading the vehicle system time, in particular at a specific factory time of a plant system

3

Method step of transmitting the vehicle system time

4

Method step of correlating the error data over the vehicle system time with specific process steps

5

Process step of recording and storing process data on process steps carried out on a respective vehicle, specifying the factory time

6

Process step of reading the error data and vehicle system times

7

Method step of generating an error list, in which each error is characterized by its frequency and its process step in which it occurs

8th

Method step of filtering the error list and optionally additionally outputting a filtered error list

10

Failure analysis device

11

error memory

12

first interface

13

second interface

14

third interface

15

clock

16

Fehlerdatenauswerteeinheit

17

display means

20

vehicle system

21

Means for detecting a vehicle system time

22

Vehicle system interface

23

on-vehicle fault memory

25

clock

30

Factory system

31

Means for recording a factory time

33

Business system interface

35

clock

36

Fehlerdatenauswerteeinheit

37

display means

40

filter

50

environmental sensor

51

Environmental sensor interface

60

Analysis of system

df

error data

dp

process data

You

environmental data

dv

vehicle data

F1, F2, ..., Fn

single detected errors

Lf

error list

asf

filtered error list

Lp

Process step list

Ptw

Process step performed at the time of a certain factory time

tf

Vehicle system time

Tf0

Start time for the vehicle system time

tw

certain factory time

tw0

Time of correlation

Tw1, Tw2, Twn

Factory time for which a process step is carried out

x

Quantity of vehicles or lot size, which can be used for the extended determination of a cause of failure

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102005037913 A1 [0005]
• DE 102005019062 B3 [0006]

Claims (13)

Error analysis device ( 10 ) for determining causes of errors in a plurality of successive process steps for assembling and / or commissioning a vehicle, wherein the fault analysis device ( 10 ) a fault memory ( 11 ) as well as an interface ( 12 ) for communication with a vehicle system ( 20 ) of a vehicle and is adapted to error data (Df) concerning errors on the vehicle via the interface ( 12 ) and in the error memory ( 11 ), characterized in that the error analysis device ( 10 ) for communication with a plant system ( 30 ) is designed, via the interface ( 12 . 13 ) to capture a vehicle system time (Tf) of the vehicle and the error data (Df) stating the vehicle system time (Tf) at which a respective error has occurred and the factory system ( 30 ) with certain process steps (Ptw) to correlate. Error analysis device ( 10 ) according to claim 1, characterized in that it is adapted to a factory time (Tw) of the plant system ( 30 ) and to correlate the error data (Df) with the corresponding vehicle system times (Tf) with the factory time (Tw). Error analysis device ( 10 ) according to claim 2, characterized in that it is adapted to correlate the error data (Df) with the factory time (Tw) and with a specific process step associated with the particular factory time (Tw), wherein for each process step Factory time (Tw) to which the process step was performed in a process step list (Lp) is assigned, and the error analysis device ( 10 ) is adapted to communicate via the interface ( 12 . 13 ) access the process step list (Lp). Error analysis device ( 10 ) according to claim 3, characterized in that it is designed as a control device or at least as a part of a control device which a first interface ( 12 ) for communication with the vehicle system ( 20 ) and a second interface ( 13 ) for communication with the plant system ( 30 ), which is designed to be connected via the second interface ( 13 ) Error data (Df) active to the factory system ( 30 ) at the time of occurrence of the respective error. Error analysis device ( 10 ) according to at least one of the preceding claims, characterized in that it has an interface ( 14 ), which is adapted to be detected by an environmental sensor ( 50 ) recorded environmental data (Du) in the fault memory ( 11 ) to deposit. Use of a fault analysis device ( 10 ) according to at least one of the preceding claims 1 to 5 in a factory system ( 30 ) for the installation and / or commissioning of vehicles, the fault analysis device ( 10 ) via a first interface ( 12 ) in communication with a vehicle system ( 20 ) and via a second interface ( 12 ) in communication with the plant system ( 30 ). Factory system ( 30 ) for determining causes of errors in a plurality of successive process steps for assembling and / or commissioning a vehicle, wherein the plant system ( 30 ) an interface ( 33 ) for communication with a vehicle system ( 20 ) or a fault analysis device ( 10 ) according to at least one of the preceding claims 1 to 5, characterized in that the plant system ( 30 ) Medium ( 31 ) for detecting a factory time (Tw) and is adapted to be connected via the interface ( 33 ) to detect a vehicle system time (Tf) and to correlate the factory time (Tw) with the vehicle system time (Tf). Method for determining causes of errors in a plurality of successive process steps for assembling and / or commissioning a vehicle, characterized by the steps: - detecting error data (Df) on errors that have occurred and storing the error data (Df) in a fault memory ( 11 ; 23 ) indicating a vehicle system time (Tf) at which a respective error has occurred; - reading the vehicle system time (Tf); Transmitting the vehicle system time (Tf) to a fault analysis device ( 10 ) or a plant system ( 30 ); - Correlating the error data (Df) over the vehicle system time (Tf) with certain process steps (Ptw). A method according to claim 8, characterized in that the correlation of the error data (Df) with certain process steps (Ptw) over a factory time (Tw) of the plant system ( 30 ), whereby the factory time (Tw) of the factory system ( 30 ) is given. A method according to claim 8 or 9, characterized in that it is carried out for a plurality of vehicles and for each vehicle each comprising the following steps: - Recording and storing process data (Dp) to executed on each vehicle process steps, indicating the specific time ( Tw) for each particular process step (Ptw); - Reading the error data (Df) and vehicle system times (Tf) from the fault memory ( 11 ; 23 ); wherein it includes for all vehicles together the following step: Generating an error list (Lf) on the basis of the error data (Df), vehicle system times (Tf) and process data (Dp), in which each error is characterized by its frequency and the process step in which it occurs. A method according to claim 8, 9 or 10, characterized in that the cause of failure is determined on an extended basis by correlating environmental data (Du) with vehicle data (Dv) and taking into account the cause of the fault as a function of the environmental data (Du) determine. Method according to one of claims 9 to 11, characterized in that the step of detecting and storing the error data (Df) by an error analysis device ( 10 ) is carried out in the form of a control device which actively sends the error data (Df) to the factory system ( 30 ) at the time of occurrence of the respective error. Fault analysis system ( 60 ) with a fault analysis device ( 10 ) according to one of claims 1 to 5 and / or a plant system ( 30 ) according to claim 7, characterized in that the error analysis device ( 10 ) Medium ( 21 ) for detecting a vehicle system time (Tf) and that the plant system ( 30 ) Medium ( 31 ) for detecting a factory time (Tw) and the fault analysis device or the plant system is adapted to associate a respective process step for assembling or commissioning vehicles with the factory time (Tw) to which the process step takes place and a vehicle system time (Tf) to which respective error has occurred is to correlate with certain process steps (Ptw).

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