IAV Primero

A Comprehensive Tool for the Entire Development Process

IAV Primero is a powerful tool that streamlines the development process of OBD systems. By simulating faults in lambda probes, you can improve the reliability and accuracy of your OBD functions. The detection of sensor functionality ensures that your sensors operate properly and provide accurate measurements. You can adjust and save the device settings with the integrated configuration editor.

IAV and KOCH Consulting have partnered to provide expert guidance and tailored advice to customers on the applications and possibilities of IAV Primero. Our collaboration allows for flexible procurement solutions, ensuring faster turnaround times and efficient service delivery.

IAV Primero offers various operating modes, including the expert mode for detailed settings, the custom mode for special requirements, the demo mode for training purposes, and the stand-alone mode for autonomous operation. You can conveniently control and monitor the remote control system from your PC or laptop. Discover the multitude of functions and the user-friendliness of IAV Primero. This tool helps you to meet the requirements of OBD development and to create high-quality vehicle diagnostic systems.

IAV Primero Features & Services

What is IAV Primero?

Fault simulation for next-generation lambda sensors. On-board diagnostics (OBD) of the lambda sensor must be able to detect ageing effects and defects in the lambda sensor in good time. This must be done before the sensor is no longer able to provide the necessary signals for emission-related functions in the vehicle (e.g. mixture control, catalytic converter diagnostics). We have redeveloped the hardware of our Primero in response to feedback from our customers. Generation 2.0 of the IAV Primero incorporates our experience of the last 20 years. You can order the IAV Primero 2.0 from 2024 and benefit from the new features.

Discover our Unique Features:

  • Manipulating signals
  • Electrical errors on wire
  • Electrical heater error
  • Availability diagnosis/loose contact simulation
  • Sensor temperature limitation
  • Remote Control via INCA-FLOW
  • Empty catalyst simulation
  • Special EMI hardened
  • Simplified sensor readiness calibration
  • Coldstart resistant

Supports the OBD development process at:

  • Tool for lambda-probes fault simulation
  • Fault simulation for up- and down-stream
  • Meets requirements of the CARB

Supports the OBD development process at:

  • Function development
  • Application
  • Homologation

The product consists of:

  • IAV Primero device in aluminium housing
  • Control-Software for pc or notebook
  • Universal connection cable
  • Carrying case

Advantages at a glance and how you can benefit from IAV Primero

  • Support for a wide range of current and future lambda sensors (via software update)
  • Efficient use of the limited test vehicles
  • Simple test execution thanks to predefined test configuration
  • Automatic and complete test documentation 

Cost-effective testing

With IAV Primero, you can save money on costly sensor replacements and make better use of their resources by using the same vehicle for different types of testing.

User-friendly device configuration

The device configuration is easy and quick to set up, even for untrained personnel, due to pre-defined configuration files created during test planning.

Accurate and automated documentation

IAV Primero automatically documents the entire testing process, including important signals, settings, and serial numbers, reducing human error and streamlining the documentation process.

Compatibility with all kind of lambda sensors

Our tool has unmatched compatibility with leading lambda probe and ecu manufacturers, ensuring that you can continue to use IAV Primero well into the future, without compatibility issues.

IAV Primero – Fault Simulation

IAV Primero GEN 1.0 vs. GEN 2.0

IAV Primero 2.0 supports current probe models and control units. Its compatibility with the new OSIC driver from Bosch is unique. Thanks to the future-proof hardware design of the Primero 2.0, future probe models can also be supported via a software update.

Some obsolete probe models are no longer supported by Primero 2.0. Please continue to use Primero of the last generation [Link to Primero 1.0/Refurbished]. Detailed information on the supported probes/driver combinations can be found in the following compatibility matrix.

Linear Probes

Binary Probes

Binary & Linear Probes

Description of Distinguished & Special Features

Counter pulse

Bosch controller units can send a so called counter pulse directly after the pulse for measuring the internal resistance of the lambda probe. This counter pulse is used to recharge the lambda probe after it was charged by the measuring current to return the correct bias of the probe. GEN2 devices can send this pulse as well and fully mimic a controller.

Pump Cell Voltage Compensation

The left over O2 in the exhaust gas correlates with the pump current. Therefore in the past only the pump current needed to be manipulated. Nowadays additional diagnostic functions of the engine controller module check for consistancy between pump cell current and voltage. In GEN2 devices the pump cell voltage can be manipulated to be in line with the manipulated pump current. With this feature it is possible to apply error patterns without triggering the new diagnostic functions as well as testing the parameters of the diagnostic functions itself.

3 kHz Capability

The ATIC-142 measures the internal resistance of the lambda probe by an alternating square signal. In the past this signal had a frequency of 750 Hz. To reduce deviations in the measured resistance, modern projects use a new default update rate of 3 kHz. GEN2 devices are capable to work with the higher frequency which leads to a closer operation nearby the ideal working point of the lambda probe (up to 10 °C less deviation).

Loose Contact Simulation

Based on new availability diagnostic functions of the engine controller modules, the GEN2 devices are capable to produce very dynamic short cuts and load dumps. With this feature it is possible to check the influences of cyclic and sporadic errors with all previous used combinations of line errors.

Weak Heater Simulation (Sensor Temperature Limitation)

By measuring the internal resistance of the nernst cell and parallel manipulation of the heater lines the GEN2 devices are able limit the sensor temperature to a certain level. This feature can be used for a proper simulation of a weak heater which is not able to heat the sensor properly.

Special EMI Hardened

It is always a challenge to develop an accurate measurement of low currents and voltages in an eletromagnetic contaminated environment. Based on the experiences from GEN1 devices in the field, the GEN2 device was designed to be more robust against EMI. Noise level and other distortions are significantly reduced. The most effect could be observed on CJ135/CJ138 during measurements.

Remote Control via INCA Flow

Beside the Start-Up Error Feature which is used to apply fixed error patterns during a test drive it is possible to control the GEN2 device via INCA Flow (Plug In for INCA). All functions of the PC GUI are available inside INCA Flow and can be combined with additional conditions for perform fully automated tests.

Coldstart Resistant

For certain testcases an error pattern for the lambda probe must be applied shortly after a coldstart of the vehicle. The GEN2 device was designed to withstand typical voltage drops during a coldstart. Therefore an external power supply is not necessary anymore.

Heater Steps < 1 Ohm

For an error pattern related to the heater prerisistor only 1 Ohm steps were possible in GEN1. Due to the change of our customers requirements (need for a higher relative accuracy) the GEN2 hardware supports steps smaller that 1 Ohm.

Simplified Sensor Readiness Calibration

The sensor readiness detection is a function of the IAV Primero to protect the sensor from damage which is caused by applying a voltage or current outside of the operational conditions. Calibrating the sensor readiness conditions which control the start and stop of the fault simulation is simplified in GEN2, because the current values and set limits are displayed inside the PC GUI.

Empty Catalyst Simulation

Beside the error simulation in lambda probes, with GEN2 it will be even possible to simulate errors related to the behavior of the catalyst. As an extreme example: To simulate an empty catalyst, the lambda value from the upstream sensor will be transmitted (with an adjustable delay and lowpass in between) to the downstream signal.

Simplified Charge Adjustment for CJ135

For each engine control module (ECM) including a CJ135 C/D/E (aka CJ135 digital) a special adjustment routine must be performed with the IAV Primero to compensate electric parasitic effects. Therefore a direct access to the internal debug signals of the ECM is necessary (which might be not desirable for the OBD demo) to adjust the GEN1 device. The GEN2 device allows to perform the same adjustment without using a special modificated development ECM.

User friendly interface

All the necessary test parameters can be set using a clear and easy-to-understand user interface. A primero configuration created in test planning can be saved and easily imported into Primero for test execution. This ensures that all tests are carried out with the correct settings and independently of the personnel carrying them out. 

Principles of Operation

IAV Primero 2.0 can be easily integrated into the signal path between the lambda sensor and engine control unit in any vehicle environment via the universal wiring harness. One linear and one binary sensor can be controlled simultaneously by IAV Primero 2.0. Configuration and control are conveniently carried out via the user interface from a laptop connected to IAV Primero 2.0 via USB. The existing CAN interface enables seamless integration of the data generated by IAV Primero 2.0 into the existing application environment (e.g. ETAS INCA). As a result, your entire test sequence is documented automatically, completely and seamlessly. 

Specific fault patterns can be implemented on customer requests

The Evolution of IAV Primero
Innovating for Over Two Decades

The new Primero 2.0 incorporates over 20 years of development experience in close collaboration with global OEMs and suppliers.

IAV Primero – Examples of fault simulation

IAV Primero 2.0 enables developers to distort the complex signal processing of lambda sensor signals in a simple way. This makes it possible to provide the OBD algorithms in the engine management system with a lambda sensor signal that can be modified by means of freely configurable error patterns. The lambda sensor signal path is distorted at vehicle level without the need to intervene in the engine control unit functions. This means that the effectiveness of the on-board diagnostics can be verified in its unchanged standard state and demonstrated as part of the vehicle approval process. IAV Primero 2.0 is therefore a tool for the entire development process – from function development, application and validation on test drives through to demonstration to the authorities as part of the approval process(COP).

Accessories

To ensure that IAV Primero 2.0 can be easily integrated into any vehicle project, a USB connection cable and a universal adapter for connection to the power supply, the engine control unit and lambda sensors are also included in the scope of delivery for IAV Primero 2.0. IAV Primero 2.0 is always supplied in a transport case.

IAV Primero – Services

Individual services offer a first-class addition to IAV Primero and enable all-round support right from the start.

Installation 
Service

  • Support of set-up at the vehicle or test stand
  • Analysing of system parameters for new sensors and control units
  • Creating suitable configuration in collaboration with our customers

Maintenance Service

  • Annual function test
  • Annual device adjustment
  • Ad-hoc device replacement service
  • Updates for the IAV Primero software

Prototype 
Service

  • Conceptual development for integration of control methods into IAV Primero for new sensors and control units
  • Modification of IAV Primero hardware and firmware
  • Validation of Measurements and Optimization of IAV Primero functionality based on customers’ requirements

Support

  • 3-Level support team daily available
  • Troubleshooting via mail, phone or screen share possible
  • Please refer to iav-primero@iav.de for all kind of requests

Training

  • Discussion of typical use cases from installation and connection to configuration and application of specified fault patterns
  • Optional discussion of advanced features like charge adaption or calibration of system configuration files
  • Demonstration of functions on desktop or in vehicle possible
  • Carried out by IAV experts and IAV developers
  • Suitable for beginners and advanced users
  • Online or on-site program available