Vehicle Embedded Health Monitoring and Diagnostic

System
The Mini-Vehicle Computer System (VCS)

Mark P. Zachos

Prasad Srinivasa

Dearborn Group Technology

27007 Hills Tech Ct.
Farmington Hills, Michigan 48331
mark@dgtech.com

Dearborn Group Technology

27007 Hills Tech Ct.
Farmington Hills, Michigan 48331
prasads@dgtech.com

Abstract This paper will cover the background, current spiral

developments, roll out, and sustainment of the US Armys newest
At-Platform Automatic Test Systems (APATS) equipment for
TWVs (Tactical Wheeled Vehicles). The equipment, called the
SWICE (Smart Wireless Internal Combustion Engine) system,
was developed for vehicle diagnostics systems in at-platform and
embedded applications, including prognostics.
Based on the WICE (Wireless Internal Combustion Engine) kit,
consisting of hardware devices, software applications and other
interface components, the Armys Product Director-Test,
Measurement & Diagnostic Equipment (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 (SWDS) 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 be presented, along
with the concept of leveraging the SWICE/SWDS as a MiniVehicle Control System (VCS).
Keywords-Vehicle Network, SWICE, SWDS, WICE, ICE,
CBM+, Mini-Vehicle Computer System (VCS), IETM, TWV,
APATS, PD-TMDE, CAISI, MIMOSA, FIPS

I.

INTRODUCTION

A. Background of ICE the US Armys 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 vehicles 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 TWVs 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.
B. 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
Armys fleet has steadily increased as new vehicles have
replaced older vehicles. Technology in general has progressed
to the extent that significant improvements can be made to the
Armys 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

978-1-4244-4981-1/09/$25.00 2009 IEEE

Authorized licensed use limited to: G H Raisoni College of Engineering. Downloaded on January 18, 2010 at 02:49 from IEEE Xplore. Restrictions apply.

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
II.

Transducer adapters that process and forward data

from legacy transducers that are part of the
diagnostics kit

SWICE Program
MSD based
Diagnostics
Software

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.
Todays 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 Armys 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 Armys 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 to
data on the vehicles networks. The Armys 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

ZigBee WL/USB

WL TK
Analog Data

WL DMM

Analog Data

MSD based
VIDS-F

Digital/Analog
Data
SWDS
* Vehicle Representation. Actual vehicle may vary

Figure 1. SWICE Program Overview

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.
A. Lose the Wires
The SWICE digital vehicle data adapter that provides
access to the data on the vehicles 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.

Authorized licensed use limited to: G H Raisoni College of Engineering. Downloaded on January 18, 2010 at 02:49 from IEEE Xplore. Restrictions apply.

Platform
RF Data Rate
Indoor/Urban
Range
Outdoor RF
Line-of-Sight
Range
Transmit
Power
Frequency
Band
Antenna
Encryption

XBee
ZB
40 m

XBeePRO ZB

XBee-PRO ZB
International
Version
250 kbps
90 m
60 m

120 m

1600 m

750 m

2 mW

50 mW

10 mW

2.4 GHz
Chip Antenna
128-bit AES
Figure 2. Zigbee Module Comparison

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 SWDS 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 Digis XBee radio
was chosen for the initial design. A few variations that were
considered are shown in Figure 2.
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.

A unique approach has been taken in the SWICE design to

address this challenge. The SWDS common hardware
platform has been designed and patented (see Figure 3.)
consisting 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.
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.
C. Go Commercial
The SWICE program completely eliminates the need for a
custom Digital Multi-Meter (DMM) that was part of the
previous ICE kits. A COTS DMM that has 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 infrared port.
D. 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.

Vehicle Connector Assembly

(VCA)
Supports:
6-Pin Deutsch (J1708)

B. 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

9-Pin Deutsch (J1708 & J1939)

DDL (ATEC & J1708)
GM UART (GMUART)
Haldex (Haldex)
Common Electronics Package
(CEP)
Supports:
All VCAs above
ZigBee & 802.11 radios
Programmable status LEDs
12

Figure 3. SWICEs SWDS Unit

Authorized licensed use limited to: G H Raisoni College of Engineering. Downloaded on January 18, 2010 at 02:49 from IEEE Xplore. Restrictions apply.

DS 1.0 Overview
DS

TK

DMM

Figure 4. SWICE Diagnostics Software (DS)

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.

Figure 5. DS Vehicle Status Overview

Figure 6. DS Vehicle Signal Monitoring

The architecture also allows for seamless enhancements and

third-party application development. Views of DS are in
Figures 5. and 6.
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
The VIDS-F and DS use Machinery Information
Management Open Systems Alliance (MIMOSA) data
standards extensively for data exchanges between themselves
as well as with other Army systems.
E. SWICE Support of CBM & CLOE
The SWICE system has been designed with both the US
Armys 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.

Figure 7. VIDS-F showing a Service Schedule Form

Authorized licensed use limited to: G H Raisoni College of Engineering. Downloaded on January 18, 2010 at 02:49 from IEEE Xplore. Restrictions apply.

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
downtime, 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 an integrated, netcentric 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. CLOEenabled 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 costeffective sustainment support.
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 SWDSs CEP utilizes Linux as its
operating system, leveraging an industry standard Operating
System (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 costeffective alternative to full-capability computers that are
installed in the vehicles for the purpose of Conditioned Based
Maintenance. The SWDSs 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 for processing and archiving, the data is

encrypted as required by Armed Forces security requirements.
The SWDS is treated as a cryptographic module with
compliance to FIPS (Federal Information Processing Standard)
140.2 Level 2.
F. 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.).

19-May-09

Vehicle Health Trend Report

Bumper Num: 29706
Signal: Fuel Pressure

PSI
16.00 12.00 8.00 4.00 0.00 .
10-Apr-09

.
24-Apr-09

.
8-May-09

Figure 8. VIDS-F Showing a Prognostics Report

Authorized licensed use limited to: G H Raisoni College of Engineering. Downloaded on January 18, 2010 at 02:49 from IEEE Xplore. Restrictions apply.

Reading
Date

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 on Integrated
Electronic Technical Manuals (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 SWICEs

SWDS

III.

FINAL THOUGHTS AND THE MINI-VCS

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 todays 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

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 Combat-Service-Support Automated
Information
System
Interface
(CAISI)
compliant
communication technology. This would create a MiniVehicle Computer System hosted on the SWDS. If direct
user interfaces are required, various existing displays and
commercial handheld devices could be leveraged.
REFERENCES
[1]
[2]
[3]
[4]

[5]

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_op
erating_environment.html>.
SAE J-1708/J-1587 and J-1939 standards.

Authorized licensed use limited to: G H Raisoni College of Engineering. Downloaded on January 18, 2010 at 02:49 from IEEE Xplore. Restrictions apply.