Monitoring based burn-in for reliability improvement of

on-board diagnostic systems

Stefano Barone*, Paolo DAmbrosio**

*University of Palermo, Italy, **University of Naples Federico II, Italy

*stbarone@dtpm.unipa.it, ** padambro@unina.it

Abstract

So they need to be decompressed in order to obtain data files for each single trip and prototype (single trip data file). This step is

New high-tech products are equipped with diagnostic systems aimed at assessing the state of health of critical components during

called data extraction and represents the first block of operations illustrated in Figure 1. The amount of files so obtained is utilised to

product life. In order to verify and improve the reliability of such diagnostics systems, a burn-in strategy can be adopted in advanced

generate a unique organised data file (data structure). This step, called data filtering, is the second block in Figure 1. Data extraction

development phases.

and filtering are performed through a graphic user interface (GUI) purposely developed in MATLAB environment (Figure 3). This GUI

In this work the authors present some results of a research work conducted in collaboration with automotive industry. Here the focus

allows engineers and experimenters to perform the above-described operations in a simple and automatic way.

is the improvement of on-board diagnostic systems of new vehicles aimed at minimising their environmental impact.

The pre-processing phase made through the

The burn-in strategy is aimed at detecting and eliminating malfunctions during a mileage accumulation campaign in which some

GUI

prototypes are tested in realistic field use.

flexible storage of the experimental data. From

A purpose-developed software enables to store experimental data collected during the mileage accumulation and to distil the

the data structure gradually built during the

necessary information for monitoring and assessing the product reliability.

MAC it is possible to obtain the time series of

A model-based monitoring approach using continuous time autoregressive models is adopted. An application concerning a new car

the diagnostic indices to monitor. Monitoring

model is presented.

the

produces

sequential,

diagnostic

monitoring

indices

both

the

coherent

and

corresponds
condition

to

of

the

antipollution components and the behaviour of

Keywords: On-Board Diagnostics; Burn-in; Statistical monitoring; Continuous time autoregressive model; Reliability improvement.

the OBD system diagnostic strategies. The

monitoring of the diagnostic indices translates

Introduction

in a suitable analysis of the time series. In fact

High technology innovative products are ever more equipped with diagnostics systems aimed at assessing the correct working of

the analysis of the time series of the diagnostic

subsystems and components. The specific assessment function of diagnostic systems is complex and critical. In fact, it is complex

indices

because based on sophisticated diagnostic strategies that process much information originating from a dynamic multi-component

improvement of the OBD system.

system ([1]). It is critical because its erroneous malfunction can cause high costs both to the manufacturer and to customers.

For instance, the analysis of time series trend

give

many

benefits

to

the

could be used to identify the degradation path

Figure 3 Purpose-developed user interface for data management

Therefore, quality and reliability of these systems must be properly evaluated before the products reach the market.

can

of a component or a subsystem and eventually

In order to assess and improve the quality and reliability of diagnostics systems, burn-in is a widely adopted engineering
methodology. Burn-in is a method used both to weed-out infant mortality by applying higher than usual levels of stress to speed up

to predict a time to failure; the analysis of mean shifts can provide information on sudden faults/failures; the analysis of variation of

the deterioration of component or system ([2], [3] and [4]) and to subject it to a period of use in realistic conditions to eliminate the

the time series can be helpful to quantify the risks related to the functioning of the OBD system and, if necessary, to improve its

potential failures in field use. In either case, burn-in may also involve continuous operational exercising and monitoring of the units

robustness against the action of sources of noise; the analysis of outliers can be useful to detect anomalous working conditions.

([5] and [6]).

The time series of diagnostic systems are

This paper briefly describes the results of the development and application of a burn-in strategy to monitor and improve the reliability

correlated

of an on-board diagnostic system (OBD) of new vehicles, conducted in collaboration with an automotive industry.

therefore to analyse them a continuous

The OBD system is the device that have to assess the state of health of vehicle anti-pollution components and subsystems, to

autoregressive model (CAR) is adopted

minimize the environmental impact of emissions. The control action of OBD systems is carried out by the calculation of diagnostics

([11]). The residuals identified by the

indices by means of algorithms implemented into the control system (or Electronic Control Unit ECU) and the following comparison

model supply much information about

of diagnostics indices values with their respective thresholds values. If a diagnostics index, indicative of the state of health of the

diagnostics

antipollution components and subsystems, exceeds its thresholds value, representative of degradation levels such to determine

stability

and

robustness

polluting emissions higher than regulatory

process

are

investigated

limits, the OBD system records a faulty

charts.

and

unequally

indices.

For

spaced,

example,
of

Origina l obs e rva tions time s e ries

0.15
0.1
0.05

the

diagnostic

via

-0.05

control

-0.1
-0.15
0

50

100

condition. Currently, in order to diagnose and

Mileage
Accumulation

fix problems potentially affecting new car

Application results

models,

An application of burn-in strategy to an

(Binary data source file)

development

oxygen

even

campaigns

the

advanced

phase,

manufacturers
Data
Extraction

during
plan

automotive

mileage

(MAC)

in

accumulation

which

fleets

of

sensor

presented.

The

diagnostic

index

diagnostic
time

series

original

index
of

is
the

x 10

150
Obs e rvation numbe r

200

250

200

250

Mileage accumula tion pa th

observations,
2

prototypes are tested in realistic field use.

recorded during a MAC interval of 60000

During the MAC, realistic conditions of use are

km, and a plot where each observations is

reproduced, specific technical tests are run

associated

and, only at prefixed mileage steps, emission

are shown in Figure 4. A first order CAR

Original Observations
Time Series
Mileage accumulation path
Box-Whiskers Plot
Outliers Scatter Plot

lab tests (New European Driving Cycle

model for oxygen sensor diagnostic index is estimated. In Figure 5 the control chart applied to residuals is shown. The stability of

NEDC) are performed.

diagnostic process, with reference to a specific mileage interval, via control chart is explored. The outlying of control points (lower

Correlation
Analysis

Original Observations
ACF & PACF
Scatter plot

improve OBD system during the MAC of new

system reliability means monitor the OBD

Conclusions

ARMA Model
Identification

Residuals
ACF & PACF
Scatter plot
Box-Whiskers plot
Histogram
Normal Probability Plot

activity to verify its correct working in realistic

Highly reliable on-board diagnostic systems require excellent system design, high quality component and optimal system integration.

use ([7]). Because the field data collected of

Our results have shown how a specific burn-in strategy based on time series monitoring is able to assess and validate the reliability

PHASE A
Data
Filtering

Preliminary
Analysis

PHASE B

System variables
monitoring

monitoring

based

burn-in

strategy,

to

50

100

150
Obs e rvation numbe r

Figure 4 - Time series and mileage accumulation path of the diagnostic index

to its corresponding mileage

limit no threshold limit) are a chance to extract strategic technological information about critical (fault) condition in system
operation in realistic filed use.

car model, is defined. Improve the OBD

diagnostics

Residuals
Control Charts

indices

are

correlated

unequally spaced time series, a specific time

systems.

series

analysis,

based

on

Continuous

Autoregressive model ([8], [9] and [10]) is

applied
Figure 1 Block diagram of the experimental data management

and the robustness of diagnostics

and

to

monitoring

the

OBD

system

Residuals
0.15

UCL

0.1

operation.

0.05

Methodology

-0.05

filter field data to support continuous improvement of the product design, integration process, component quality and the burn-in

-0.1

process itself. Therefore, to this purpose, it is standard practise for manufacturers to plan accurate MAC in which some prototypes of

-0.15

a new vehicle are used in realistic condition accumulating a certain prefixed mileage. A MAC usually requires the accumulation of

the

strategy

presented

allows

to

detect

anomalous

behaviours

control

points)

system

and

of
to

(out

diagnostics
validate

about

of

its

specific

kilometres interval.
Key attributes of a successful and
efficient

LCL
30

60

90

120

150

about a hundred thousands kilometres and can last several months to be accomplished. Using specific devices on board of the

burn-in

strategy

are

realistic field application conditions,

180

210

240

270

Observation number

vehicles, it is also possible to acquire information on the activity of the OBD system in order to monitor its correct working.

fact,

operation

The primary goals of the burn-in strategy developed are not only to deliver highly reliable products but also to collect, storage and

In

Figure 5 Control charts applied to estimated residuals

high quality data collected and

analyzed

and

strategy

itself

continuously improved.

Consequently, if the monitoring activity is extended to a wide mileage interval, a big amount of experimental data is collected.
A management strategy of the
experimental data coming from

References

the MAC has been conceived. It is

Legend

illustrated in the block diagram of

Figure 1. The strategy develops

Data extraction

Binary data source file

Prototype 1

Data filtering

first

phase

the

Prototype 1; Trip N1

information

coming from the proceeding of

Prototype 2

the MAC is organised in a data

structure

for

an

efficient

and

effective analysis; in the second

phase
analysed
statistical

organised
through

data

are

suitable

methodologies.

The

Data structure
Accumulation

Binary data source file

Elementary data file
Prototype 2; Trip N2

.name
.variable (k)

.name
.description

.sampling (k)

.project
.prototype

...

.informations

Prototype M

.project
.legend

vol. 51, pp.1090-1101

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Figure 2 - The data structure obtained from the experimental data

and by fixing the variables to

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8th International Conference QMOD, Palermo (Italy), 29th June 1st July 2005