Published by Hyundai Motor company, september 2005 MDPS Column Assist Type Electric Power Steering MC (Accent) MDPS

2 Introduction Application

SubjectIntroductionMC-MDPS Target Audience Instructors at OTC, RTC, Distributors Field technicians Objectives Understand the application for MDPS of MC and TB F/L Understand the model line-up and system supplier Instructor notes MDPS option rate by customer for the current TB model: only 3% (less than) it is the reason why MDPS is compulsory selected as a standard option on MC and TB F/L U-1.5. MC All models: It is applied as a standard option except North American market. TB F/L (D-1.5 Diesel): It is applied as a standard option. Even though the system supplier is different; MC (MANDO), TB and TB F/L (Koyo Seiko – Imported from Japan), The control system is nearly same between two models. Because the supplier for MDPS control module is same MELCO (Mitsubishi). Why there are two vendors for the similar system? Its reason is a matter of the agreement with the supplier. MDPS is not applied in RHD. (Because of the layout – space, interference) *Caution: This may be changed prior to manufacturing for the sales planning. Material requires Training Slide, Textbook Time5 minutes

4 Components EPS Motor ECM Torque Sensor Reduction Gear Introduction

SubjectComponentsMC-MDPS Target Audience Instructors at OTC, RTC, Distributors Field technicians Objectives Understand the components for MDPS of MC and TB F/L Main function for each system components Instructor notes Steering Gear ratio (Refer to the table) Reduction gear Ratio: MC (16.33) TB (13.67) Material requires Training Slide, Textbook Time 5 minutes

6 Torque sensor Specification Position rotor Torque rotor - Operating Temp. : -40° to 85°C - Supply Voltage : 5V - Resistance Range : 540KΩ - Detection angle : ±8 deg

7 Structure Torque sensor

SubjectTorque sensorMC-MDPS Target Audience Instructors at OTC, RTC, Distributors Field technicians Objectives Understand the operating principle for MDPS torque sensor The difference between MC and TB Instructor notes The torque sensor for TB is a non-contact type but MC has a contact type torque sensor (Potential-metric: Variable resistance type). It consists of two rotors, position rotor and torque rotor. It is not allowed to disassemble this sensor from column shaft. As same as in the case of TB, this sensor also outputs two signals such as Main and Sub signal; both signals have an opposite phase each other when the specific torque is applied on the torsion bar. When the steering wheel is in the neutral position, that is no torque is detected the output voltage will be 50% of power supply voltage (2.5V). The sensor output voltage is limited by the rotating range of the inner shaft because it is restricted by the stopper. The maximum detection angle for this sensor is ±8° but actually its limitation is ±4.5° due to the reason of mechanical structure. All the diagnostic trouble code in this system will be erased by scanner, or if the following condition is satisfied it also will be erased naturally. The system power supply on and off is repeated without trouble for 60cycles or more. Material requires Training Slide, Textbook Time 5 minutes

9 Zero torque Sensor signal (Main, Sub) 0.4V < Main, Sub Signal < 4.6V Torque sensor

10 Failsafe Main Sensor output > 4.6V or < 0.4V Motor Off, Relay Off, Warning lamp ON [C1290] Sub Sensor output > 4.6V or < 0.4V Motor Off, Relay Off, Warning lamp ON [C1291] Absolute value of (Main sensor – Sub sensor) > 0.527V Motor Off, Relay Off, Warning lamp ON [C1292] Torque Sensor supply voltage > 5.7V or < 4.3V Motor Off, Relay Off, Warning lamp ON [C1112] Failsafe will be restored if the system power is off. Torque sensor

11 Motor Specification

SubjectMotorMC-MDPS Target Audience Instructors at OTC, RTC, Distributors Field technicians Objectives Understand the Characteristics for MDPS motor Instructor notes To guarantee stable and reliable steering performance, the motor capacity of current has been increased from 45A into 65A comparing with the one for TB. - TB, TB F/L [Koyo Seiko] Gasoline (45A), Diesel (60A) - MC [MANDO] Gasoline and Diesel (65A) If the motor current is higher than 73A, the DTC will be detected and the motor will be off. (warning lamp turns on) Material requires Training Slide, Textbook Time 3 minutes

13 No. 1Drop Check item Check at drop onto working bench. Test result The noise shall be measured when assy is dropped onto working bench(with rubber mat). Test method Height = 500mm Noise level = 12% Up Drop2 Check at drop onto floor(concrete). The noise shall be measured when assy is dropped onto floor(concrete). 3Drop Check at drop onto floor(concrete). The noise shall be measured when yoke end is impacted against iron block. Height = 100mm Noise level = 13% Up Height = 100mm Noise level = 11% Up height Rubber mat Bench height Floor(concrete) height Iron block Noise Motor

14 Failsafe Motor voltage on both sides > 8.5V or < 0.2V Motor Off, Relay Off, Warning lamp ON [C2412] Measured current – Target current > 10A Motor Off, Relay Off, Warning lamp ON [C2413] Motor current is higher than 73A Motor Off, Relay Off, Warning lamp ON [C2414] Measure motor current < 2A when the target current is higher than 4A Motor Off, Relay Off, Warning lamp ON [C2415] Failsafe will be restored if the system power is off. Motor

SubjectMotorMC-MDPS Target Audience Instructors at OTC, RTC, Distributors Field technicians Objectives Understand the failsafe for MDPS motor Instructor notes 1) C2412 (Error in the motor voltage) When the motor is not operated if Motor voltage on both sides > 8.5V or < 0.2V for 0.5seconds. (Must be normally 1V) Failsafe control: Motor Off, Relay Off, Warning lamp ON 2) C2413 (Error in the motor current) This failure is detected if (Measured current – Target current) > 10A Failsafe control: Motor Off, Relay Off, Warning lamp ON 3) C2414 (Excessive motor current) This failure is detected if the motor current is higher than 73A. Failsafe control: Motor Off, Relay Off, Warning lamp ON 4) C2415 (Measured motor current error) This failure is detected if Measure motor current < 2A when the target current is higher than 4A for 2.4seconds or more. Failsafe control: Motor Off, Relay Off, Warning lamp ON Material requires Training Slide, Textbook Time 3 minutes

16 Power supply Failsafe Excessive battery power: > 17.5V Motor Off, Relay ON, Warning lamp ON [C1101] Low battery power: < 10V Low motor current, Relay ON, Warning lamp ON [C1102]

17 Engine speed signal SignalFailsafe Idle speed Engine speed is lower than 330rpm when the vehicle speed is higher than 50km/h. Motor Off, Relay ON, Warning lamp ON [C1272]

SubjectEngine speed signalMC-MDPS Target Audience Instructors at OTC, RTC, Distributors Field technicians Objectives Understand the output signals of engine speed for MDPS control Failsafe function when the engine speed signal is malfunctioned. Instructor notes 1 Hz of frequency 30 rpm (engine speed) C1272 (Engine speed signal failed) This failure is detected if the engine speed is lower than 330rpm when the vehicle speed is higher than 50km/h for 20seconds. Failsafe control: Motor Off, Relay On, Warning lamp ON It will be restored if the engine speed is higher than 525rpm or the system power supply is off. Idle up compensation for MDPS: It will not be applied in case of MC. (idle up will result noise and vibration) Material requires Training Slide, Textbook Time 3 minutes

19 Vehicle speed signal SignalFailsafe Vehicle speed is 0km/h when the engine speed is higher than 2,500rpm for 20seconds. Motor is controlled as 255km/h, Relay ON, Warning lamp Off [C1212]

SubjectVehicle speed signalMC-MDPS Target Audience Instructors at OTC, RTC, Distributors Field technicians Objectives Understand the output signals of vehicle speed for MDPS control Failsafe function when the vehicle speed signal is malfunctioned. Instructor notes Hz of frequency 60km/h (vehicle speed) This failure is detected if the vehicle speed is 0km/h when the engine speed is higher than 2,500rpm or more for 20seconds. If the engine is just started, following conditions must be satisfied for the DTC to be detected. Vehicle speed = 0km/h, Engine speed > 4,000rpm for 5minutes Failsafe control: Motor is controlled as 255km/h, Relay ON, Warning lamp off It will be restored if the vehicle speed is higher than 5km/h or the system power supply is off. The vehicle speed signal is not a critical factor for the safety in this system, therefore the motor will not be turned off even though the sensor signal is failed, and however the current will be decreased in order to make the steering effort to be increased. Material requires Training Slide, Textbook Time 3 minutes

21 MDPS control module Failsafe Failsafe relay stuck Motor Off, Relay Off, Warning lamp ON [C1704] Internal power supply < B+ Motor Off, Warning lamp ON Motor voltage > 23V Motor Off, Warning lamp ON ASIC or torque sensor interface failed Motor Off, Warning lamp ON Thermistor temperature < -50°C Controlled as 60°C, Warning lamp Off [C1604]

SubjectMDPS control moduleMC-MDPS Target Audience Instructors at OTC, RTC, Distributors Field technicians Objectives Understand the system feature for MDPS control module Failsafe function when the control module is malfunctioned. Instructor notes 1) C1704 (Failsafe relay stuck) This failure is detected if failsafe contact voltage > 5.5V for 5seconds. (Motor Off, Relay Off, Warning lamp ON) 2) C1604 (MDPS control module internal failure) This trouble code will be detected when the following conditions are satisfied. a) Internal step-up power supply output voltage < Battery voltage for 2seconds or more. Failsafe control: Motor Off, Relay ON, Warning lamp ON b) The voltage at the motor monitoring interface terminal > 23V or < -3V Failsafe control: Motor Off, Relay Off, Warning lamp ON c) ASIC failure (Failsafe control: Motor Off, Relay Off, Warning lamp ON) d) Torque sensor interface failure (Failsafe control: Motor Off, Relay Off, Warning lamp ON) e) Thermistor failure: Detected temperature < -50°C Failsafe control: Motor is controlled as 60°C, Relay ON, Warning lamp Off f) ROM or RAM failure (No DTC) : Failsafe control: Motor Off, Relay Off, Warning lamp ON Material requires Training Slide, Textbook Time 5 minutes

23 Scanner (Hi-scan Pro) Service (Current) data

SubjectScanner (Hi-scan Pro)MC-MDPS Target Audience Instructors at OTC, RTC, Distributors Field technicians Objectives Understand the meaning of all items displayed on the current data menu of Hi-scan Pro. Instructor notes In case of MDPS, it is possible to communicate with Hi-scan without CAN interface module. - It uses independent K-line for the communication with the scanner. The menu of ECU initialization will be eliminated soon from the final version software. - Different part number for MDPS control module (Domestic, EU/General). - The steering effort for EU/General is more high than domestic. - But TB will still have a menu for shifting the mapping data using the scanner. The maximum motor current is about 60A. (even though its maximum capacity is 65A) - When the overheat protection is not activated and the steering wheel is fully turned (maximum torque). Consigned power: this means the target motor current Material requires Training Slide, Textbook Time 5 minutes

25 Scanner (Hi-scan Pro) Overheat Protection

SubjectScanner (Hi-scan Pro)MC-MDPS Target Audience Instructors at OTC, RTC, Distributors Field technicians Objectives Understand the logic of overheat protection Instructor notes As same as one for TB, there is a thermistor detects overheat inside control module in this system. If the temperature is higher than the specified value, the motor current will be decreased in order to protect the system hardware for the safety. Therefore the steering effort will be increased but it is not a failure but the system will be restored as the temperature decreases. The minimum motor current is decided according to the temperature measured by thermistor inside control module. Material requires Training Slide, Textbook, Video file attached in the slide Time 5 minutes