Vehicle Embedded Health Monitoring and Diagnostic System

M. Zachos and S. Prasad

Dearborn Group Technology
248.488.2080 www.dgtech.com
mark@dgtech.com prasads@dgtech.com

Abstract

This paper will cover the background, current spiral developments, roll out, and
sustainment of the US Army’s newest APATS equipment for TWVs. The
equipment, called the SWICE system, was developed for vehicle diagnostics
systems in at-platform and embedded applications, including prognostics.
Based on the WICE kit, consisting of hardware devices, software applications
and other interface components, the PD-TMDE supported SWICE kit provides a
low cost Embedded Computer System supporting CBM (Condition Based
Maintenance) system deployment.
An overview of the SWICE system operation is described, including the Smart
Wireless Diagnostic Sensor (S-WDS) device, features of the Vehicle Integrated
Diagnostics Software-Field (VIDS-F) implementation, and the vehicle Diagnostics
Software (DS) application. Also covered will be the functions of the Prognostics
Client "plug-in" module and integrated support for the Common Logistic
Operating Environment (CLOE) implementation.
Finally, the potential for coordinating new industry standards for developing
common prognostic functions via IEEE, SAE, ISO, and other allied standards
organizations will also be presented.

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1. Introduction
1.1. Background of ICE – the US Army’s TWV APTS
The US Army has developed a test platform, termed the ICE (Internal
Combustion Engine) kit or system, for the maintenance of their fleet of tactical
wheeled vehicles (TWVs). This Army fleet consists of vehicles from various
manufacturers utilizing varying technologies, depending upon the type and age of
each particular vehicle platform. To ensure meeting the maintenance
requirements of all of these vehicles as a whole, the ICE system combines the
use of analog data with digital data; all accessed via the vehicle’s data
network(s).
Users seeking access to these data utilize the ICE software, whose features
range from simply monitoring vehicle parameters to running complex special
tests that use data from multiple vehicle network/component sources.

The ICE system is packaged with all of the equipment required for the TWV’s
maintenance in a single kit, consisting of:

 Hardware for interacting with TWVs vehicle network(s)

 Hardware to interface to the vehicle analog data port
 Hardware with multi-meter capability
 Various transducers and cables
 Software that communicates with the vehicle, manages vehicle data from
multiple sources and assists in maintenance of the vehicle.

1.2. After ICE

While the ICE system has served the purpose it was designed for, over time it
has offered important pointers for the future of computer based vehicle
maintenance systems. Added to this is the fact that the electronic content of the
Army’s fleet has steadily increased as new vehicles have replaced older vehicles.
Technology in general has processed to the extent that significant improvements
can be made to the Army’s vehicle maintenance systems. Some of the areas of
improvement identified include:

 Size and weight reduction to help greater mobility

 Alternatives to wired connections improving ease of use of the systems
 Better integration of applications used for procedural troubleshooting, data
archival and the like for improved efficiency
 Support for new areas of fleet maintenance such as Condition Based
Maintenance (CBM) based on data analysis to enable future systems

Taking these factors into consideration, the US Army has charted a new path for
maintenance solutions. These are designed to leverage state-of-the-art
technology available in the commercial world and address some of the
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improvements and new ways of addressing the maintenance needs described
above.

2. The New Direction – SWICE

The goal of the Smart Wireless ICE (SWICE) program is vehicle embedded
health monitoring and diagnostic systems for TWVs that implements appropriate
improvements to the ICE Kit.
Today’s military vehicles have sophisticated on-board computers, interworked via
vehicle networks, controlling the functions of various systems on the vehicle.
These systems include engine, transmission, braking, and other electronic
controlled specialty devices. In summary, there is a wealth of information
available on vehicle networks that can be used for diagnostics, CBM and
prognostics.

The SWICE system, at a minimum, addresses:

 Removing dependence on the wired connection to attain vehicle data by

providing wireless connectivity, while still maintaining the connection
reliability and supporting the Army’s data security needs.
 Significantly reducing the overall size and weight of the maintenance kit
 Adoption of “Commercial Off-The-Shelf” (COTS) equipment where
possible to minimize the need and use of customized systems
 Integrating functionality of various applications with overlapping
functionality into one user-friendly solution to help with shorter training
demands and higher efficiency of use
 Providing a platform for Conditioned Based Maintenance (CBM) based on
the Army’s Condition Based Maintenance Plus (CBM+) program and the
Common Logistic Operating Environment (CLOE) implementation

The key components of the SWICE system maintenance kits are:

 Digital vehicle data adapter that provides access the data on the vehicle’s
networks. The Army fleet of TWVs requires support for 5 different vehicle
network protocols, including the popular J1939 and J1708 protocols. The
diagnostic connectors on the vehicles are different, depending on factors
like manufacturer, type of vehicle and the diagnostics protocol supported.
 Analog vehicle data adapter that provides access to data available via the
analog data port in the vehicles. There is a wide array of signals available
with different ranges and signal conditioning requirements that the adapter
needs to address
 Transducer adapters that process and forward data from legacy
transducers that are part of the diagnostics kit
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  A digital multi-meter that is integrated into the kit; both physically and
functionally
 Diagnostics software that not only provides access to all the above
devices but also integrates diagnostics functionality from various legacy
applications
 An “interrogator” that enables the host computing device to communicate
with the SWICE components

The design of these SWICE components has been undertaken to clearly address
the aforementioned SWICE system goals, and is shown in Figure 1. We will now
step through the design considerations.

Figure 1 – SWICE Program Overview

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 2.1 Lose the Wires
The SWICE digital vehicle data adapter that provides access the data on the
vehicle’s networks is called a Smart Wireless Diagnostics Sensor (SWDS). The
wireless technology chosen for the SWDS to eliminate the wired connection to
the vehicle must consider multiple usage scenarios:

1. At-platform mode: In this application, the SWICE components are used by

Army motor pool technicians to read data, diagnose, and repair on-vehicle
electronic systems, typically in a service bay environment.
2. Guard post mode: In this mode, SWICE wireless modules are
permanently installed on the vehicle and continuously monitor the health
of electronic systems on the vehicle. As vehicles enter within radio range
of a guard post, vehicles are interrogated by a guard post computer to
determine if the vehicle is functioning properly and determination is made
as to the fitness of the vehicle to leave the base.
3. Convoy mode: In this mode, the SWICE components are permanently
installed on the vehicle and continuously monitor the health of electronic
systems. Convoy Mode allows a computer, mounted in a lead vehicle, to
monitor the health of all vehicles in a convoy via wireless technology,
when the convoy is deployed in the field.

While Zigbee wireless technology is the most appropriate initial wireless

technology, the design has been modularized to enable implementing other
wireless technologies, including various instances of 802.11, with very minimum
or no impact to the hardware, firmware or software. Zigbee wireless is a very
mature technology with wide implementation in the commercial industry, and
supports all the required parameters with regard to distance, reliability, power,
and mesh networking.

Many Zigbee radios were reviewed and Digi’s XBee radio was chosen for the
initial design. A few variations that were considered are shown in Figure 2.

Platform XBee ZB XBee-PRO ZB XBee-PRO ZB

International
Version
RF Data rate 250 kbps
Indoor/Urban Range 40 m 90 m 60 m
Outdoor RF Line-of- 120 m 1600 m 750 m
Sight Range
Transmit Power 2 mW 50 mW 10 mW
Frequency Band 2.4 GHz
Antenna Chip Antenna
Encryption 128-bit AES

Figure 2 – Zigbee Module Comparison

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While the XBee-PRO ZB International version has been used in the current
implementation, a wired USB communication capability is maintained as a
backup communication channel. This interface can also be used for
implementation of features that may be deemed impractical for wireless
communication.

2.2 Weight-Loss Program

In an effort to reduce the size and weight of the SWICE kit, a number of design
options have been exercised. Due to the nature of the vehicles in the fleet
supporting different vehicle network protocols and requiring different connectors
to gain access to the vehicle networks, any practical solution needs to provide
multiple connector options. In the past, this has been typically addressed by
providing a different cable set for each connector variation and, as a result, adds
significant weight to the kit

A unique approach has been taken in the SWICE design to address this
challenge. A common hardware platform called the SWDS has been designed
and patented. The SWDS (see Figure 3) consists of a CEP (Common Electronics
Package) that provides the central processing power and the host
communication capabilities, discussed later. Several VCAs (Vehicle Connector
Assemblies) can be attached to the CEP. This design approach reduces cost by
not only removing redundant computing power, it eliminates the need for cables
and provides a quick swap mechanism to change connectors. The SWDS plugs
directly into the appropriate vehicle network port without a cable.

Figure 3 – SWICE’s SWDS Unit

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This concept has been further advanced to include all of the analog interface
capabilities as another VCA so that the special analog hardware can also be
completely eliminated. Additionally the analog circuitry is being miniaturized to be
embedded into the analog connector body, thereby reducing additional size and
weight.

2.3 Go Commercial
The SWICE program completely eliminates the need for a custom Digital Multi-
Meter (DMM) that was part ICE/previous kits. A COTS DMM that has all of the
capabilities required of SWICE has been integrated into the kit. To enable this
integration, a wireless adapter has been designed that attaches to the COTS
DMM and becomes an integral part of the SWICE. The communication between
the DMM and the wireless adapter is achieved via an infra-red port.

2.4 Software Integration

The US Army vehicle maintenance procedures use a multitude of applications,
each performing a subset of the overall functionality. Among these, there are
applications catering to basic vehicle parameter monitoring, some special tests
and fault detection/resolution features. There are other advanced applications
that provide data archiving, data trending and data analysis functionality.

Figure 4 – SWICE Diagnostics Software (DS)

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Figure 4 shows the Diagnostic Software (DS), here running on a military-grade
laptop computer known as a Maintenance Support Device (MSD). Part of the
SWICE solution, DS integrates the functionalities of these varied applications and
provides a single platform for implementation of complete diagnostics strategies.

The DS provides capabilities for:

 Vehicle identification
 Vehicle fault detection and analysis
 Vehicle data monitoring (digital and analog)
 Vehicle data archiving
 Special test routines
 Data forwarding for fleet maintenance

In addition DS implements advanced diagnostics concepts including smart hand-

off, prognostics and convoy mode operations. The DS server is architected in the
client-server model where a high degree of decoupling has been achieved
between the presentation and data processing layers. This is done with a clear
intention of having the option to port the application to alternate operating
platforms and embedded systems. The architecture also allows for seamless
enhancements and third-party application development. Some example views of
DS follow.

Figure 5 – DS Vehicle Status Overview

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 Figure 6 – DS Vehicle Signal Monitoring

A Vehicle Integrated Diagnostics Software fleet management application (VIDS-

F) is a companion application to the DS that will be used by vehicle pool
managers to track and maintain the health of all the vehicles in the fleet. The
VIDS-F (Figure 7) closely integrates with the DS data and provides these
additional features:

 Vehicle fleet health monitoring

 Vehicle maintenance scheduling and tracking
 Prognostics
 Fleet reports
 Interface to Army order processing applications

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 Figure 7 – VIDS-F showing a Service Schedule form

The VIDS-F and DS use MIMOSA data standards extensively for data exchanges
between themselves as well as with other Army systems.

2.5 SWICE Support of CBM, CLOE

The SWICE system has been designed with both the US Army’s CBM+ and
CLOE programs in mind. While these programs are being implemented to
improve overall vehicle availability and reliability, they also save resources and
expenditures.

First, a little background on CBM and CLOE is in order. With the quantity and
quality of data that the vehicle generates and communicates to external
diagnostics devices, CBM (Condition Based Maintenance) of the fleet of vehicles
as opposed to scheduled maintenance has become more practical. CBM
reduces maintenance costs by avoiding unnecessary maintenance and reduces
equipment failure, and hence down-time, by predicting failure based on data
parameters and enabling preventive maintenance on a new schedule based on
conditions (data).

Regarding CLOE, this is the Army G-4's initiative to synchronize logistics

concepts, architectures, organizations, and a new generation of technologies into
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an integrated, net-centric logistics domain. The CLOE documents the Army's
logistics information infrastructure, from the weapon system up through the
national level. The ultimate goal is to enable operational commanders and
logisticians at all levels to have total situational awareness within a common
operating picture for all aspects of logistics, from factory to foxhole.

At the national level, CLOE-enabled data flows will enhance fleet trending and
analysis, reliability growth, adjustments to maintenance programs, and true
prognostic capabilities that will leverage information resources to provide
substantially better and more cost-effective sustainment support. Additionally,
CLOE-enabled capabilities will assist Performance Based Logistics (PBL) by
providing contractors the information necessary to optimize system readiness.
The CLOE technologies mark a step change in sustainment processes that will
enable improvements in vehicle readiness, availability, and mission performance
by providing commanders, operators, and maintainers enhanced capabilities to
monitor and assess mission critical data onboard the platform.

So, just how does SWICE help with regard CBM and CLOE? The SWDS
component of SWICE has been designed to support CBM, by providing the
processing power, data storage capabilities, communication throughput and
software architecture to enable easy implementation, enhancement and
maintenance of CBM components.

Additionally, the SWDS’s CEP utilizes Linux as its operating system, leveraging
an industry standard OS, its open architecture and many plug in modules readily
available for a host of processors. This open architecture coupled with a standard
development environment allow for easily scaling the solution to fit the exact
needs of the vehicle maintenance solution space.

The SWDS is designed to be permanently fitted in the vehicle, and can be

leveraged as a CLOE and CBM host/processing device. In this mode of
operation, it is a cost-effective alternative to full-capability computers that are
installed in the vehicles for the purpose of Conditioned Based Maintenance. The
SWDS’s CEP is designed with leading-edge processing power to:

- Monitor the vehicle network

- Monitor the analog diagnostics signals
- Process and archive the data*
- Provide visual indication of vehicle faults
- Communicate with external applications over wired or wireless links
- Host CBM and CLOE applications and more

*Note that data is encrypted as required by Armed Forces security requirements. The SWDS is
treated as a cryptographic module with compliance to FIPS 140.2 Level 2.

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 2.6 SWICE & Prognostics
The SWICE architecture, and specifically the SWDS component architecture,
lends itself to support of Prognostics, which is the proactive approach to
anticipate vehicle problems and take timely action to prevent it. The SWDS will
implement a Prognostics Host with a published specification for designing
prognostics modules that can then be hosted on the SWDS. At a minimum, the
Prognostics Host will marshal the vehicle data, both digital and analog and make
it available to the prognostics modules for processing. It will also provide a
framework for the prognostics module to communicate with other externally
hosted applications that can be used for further processing the data, and
interacting with the user. All data will conform to MIMOSA standard that is
emerging as a strong contender for standardizing diagnostics and prognostics
related data, and will help in CLOE support.

With this plug-in approach, third-party prognostics algorithms can be hosted on

the SWDS. This will enable vehicle engineers to develop prognostics logic
without having the need to be bogged down by details regarding vehicle
networks, and operating environments, allowing them to efficiently generate
system independent prognostics algorithms. This process can be further
simplified by Prognostics Algorithm authoring applications that could allow
prognostics algorithms to be generated and tested within a very short-time.

The DS software compliments this prognostics approach by providing facilities for

upload/download of algorithms, enable/disable algorithms and uploading CBM
related data and forwarding to VIDS-F for fleet analysis (see Figure 8).

Figure 8 – VIDS-F Showing a Prognostics Report

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3. Summary and Conclusion
The SWICE effort capitalizes on the lessons learned from the previous ICE and
WICE (Wireless ICE) solutions and incorporates state-of-the-art technologies to
meet the stated goals of the today’s and future diagnostics solutions. Where
possible, COTS equipment has been used and the hardware and software
architectures have been modularized to allow for easy scalability to incorporate
future enhancements. The CBM infrastructure allows for experts to author CBM
algorithms to be hosted on SWICE hardware, the SWDS.

As the CBM concepts mature, it may be possible to standardize CBM algorithms

and publish them as SAE or IEEE standards. This will enable adoption of
SWICE- like solutions to provide coverage for a wider range of vehicles, both
military and commercial.

Figure 9 depicts various existing and emerging CBM applications running on the
SWICE SWDS. Utilizing the processing power of the SWDS, not only can
existing vehicle network data, vehicle specific information (IETM), and sensors
be accommodated, but emerging CBM applications can be hosted on the vehicle
network port-mounted SWDS.

Figure 9 – Existing & Emerging CBM Applications Hosted on SWICE’s SWDS

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There is also potential for the SWICE to take on some of the work handled by the
VCS (Vehicle Computer System) with the integration of CAISI compliant
communication technology. This would create a “mini Vehicle Computer System”
hosted on the SWDS. If direct user interfaces are required, various existing
displays and commercial handheld devices could be leveraged.

4. References
 Simplified Test Equipment/Internal Combustion Engine (STE/ICE)
 SAE J-1708/J-1587 and J-1939 standard
 MIL-STD-810F, Environmental Engineering Considerations and Laboratory
Tests
 MIL-STD-461E, Requirements for the Control of Electromagnetic Interference
Characteristics of Subsystems and Equipment
 MIL-STD-464A, Electromagnetic Environmental Effects, Requirements for
systems
 "2009 U.S. Army Posture Statement." The United States Army Homepage. 21
July 2009
<http://www.army.mil/aps/09/information_papers/common_logistics_operating
_environment.html>.

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