Design Requirements for Automotive Reliability
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Robert BOSCH GmbH, Automotive Electronics
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
Design Requirements for Automotive Reliability
Valentin von TilsDirector Platform Development ASICs
ESSDERC 2006,Montreux, SwitzerlandSeptember 22, 2006
2 AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
Design Requirements for Automotive Reliability
Automotive Electronics in German Newspapers (2003)
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Design Requirements for Automotive Reliability
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
Outline
Journey from Yesterdays Vision to Today‘s World
Requirements for Future Systems
Expected Market Trends
Reliability Trends
Impact on Power Semiconductors
Summary
4
Design Requirements for Automotive Reliability
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
1960: Vision
“The development of semiconductors is just at the beginning…
Using semiconductors, ideas like electronic gasoline injection as well as control systems that allow steering, accelerating and braking through a small control stick, orsteering systems that guide the car automatically on the road, or radar units that show obstacleseven in dense fog, as well as some others, can become reality…
Electronics is starting to change and to improve the electric vehicle system and is thus adding increased safety to the car.”
source: R. Bosch GmbH, Dr. Callsen, „The Importance of Semiconductors for the Electrical Vehicle Equipment“. FISITA congress, 1960.
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Design Requirements for Automotive Reliability
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Automotive Electronics
Automotive Electronic Yesterday ...
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Design Requirements for Automotive Reliability
Semiconductor History 20th Century
Silicon DiodeMass Production
ICDevelopment
60‘s50‘s
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Germanium Diode
Development&
Start of MassProduction
70‘s
ICMass Production
MOS-ICDevelopment
Automotive Electronics
Pressure SensorsMikro Mechanical
6“-Wafer FabOpening
90‘s80‘s
MOS-ICMass Production
Opening of MicroElectronics
Technical Center
50 years ofAutomotive Experience
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Design Requirements for Automotive Reliability
Milestones of automotive technology
1897 1902 1951 1967 1976
Low-voltage magneto ignition for vehicles
High-voltage magneto ignition with spark plugs
Diesel injection pump
Gasoline injection pump for cars
Electronic gasoline injection (Jetronic)
Lambda sensor for three-way catalytic converter
Antilock braking system (ABS)
1927
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1978
Automotive Electronics
1933
Acquisition of Ideal-Werke, today's Blaupunkt GmbH
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Design Requirements for Automotive Reliability
Milestones of automotive technology
1991 1995 1997 2001 2002
Combined digital control of gasoline injection and ignition (Motronic)
• Electronic stability program (ESP) • Vehicle navigation system with voice guidance
Common-rail high-pressure injection system for diesel engines
Electrohydraulic brake
Electronic battery management (EBM)
• Electronic diesel injection (EDC)• Traction control system (TCS)
Controller Area Network (CAN)
Third generation common-rail technology, with piezo in-line injectors
1979 1986
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
2003
Automotive Electronics
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Automotive Electronics
Design Requirements for Automotive Reliability
EngineManagement
Emission control
Interior Sensing
Traction Control System
Chassis Control
Anti-lock Braking System
Electronic Stability Program
Airbag electronics, safety belts,over-roll Bar
Cruise Control
Navigation Park-Pilot
Electronic power steering
ca. 30 electric/electronic systems,50-100 micro processors,
>100 sensors within modern mid-size cars
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Design Requirements for Automotive Reliability
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
Traffic Density vs. Car Safety
Seat-Belts
Airbag Side-Airbag ESP
ABS
Sources: “Statistisches Bundesamt“ and Bosch
% Change (1970 = 100%)
0%
50%
100%
150%
200%
250%
300%
1970 1975 1980 1985 1990 1995 2000 2005
Traffic DensityTotal AccidentsInjuredKilled
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Design Requirements for Automotive Reliability
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Automotive Electronics
Reduction of Pollution (caused by cars)
all numbers = limit values in g/km
100
100
100
1990 1995 2000 2005CO0
50
50
50
0
21,2ECE R15/04
2,72 1,0 0,64 0,50
97% 98%
EU1
EU30,196
0,140,10
0,05 0,025EU4Particles
EU2
State-of-the-art2004
81% 91%
5,8ECE R15/04
1,36 0,97 0,90 0,56 0,300
90% 95%
HC + NOX
0,2788/436/
EEC
%
12
Design Requirements for Automotive Reliability
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
Reduction of Fuel Consumption
6,0
6,5
7,0
7,5
8,0
8,5
9,0
9,5
10,0
10,5
11,0
1978
1980
1982
1984
1986
1988
1990
1992
1994
1996
1998
2000
2002
1/3-MixNEFZ
Fuel
cons
umpt
ion
[l/10
0km
]
Catalyser Diesel DIE-Gas
Common Rail
BDE
Source: VDA
35%
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Design Requirements for Automotive Reliability
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Automotive Electronics
„Intelligent Vehicle“
Airb
agSy
stem
Therm.
System
Kinetics
internal
data
Environ
ment
Position
Tele-maticInfo.
Engine
Brake
System
Steering
System
Trans-missionElectr.System
VehicleFunctions
"IntelligentSensors"
"IntelligentActuators"
HumanMachineInterface
Mon
itorin
g
Fusi
on,
Con
solid
atio
n
Coordination
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Design Requirements for Automotive Reliability
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
Outline
Journey from Yesterdays Vision to Today’s World
Requirements for Future Systems
Expected Market Trends
Reliability Trends
Impact on Power Semiconductor
Summary
15
Design Requirements for Automotive Reliability
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
The Future of Automotive Electronics
“The number of ECUs in the car will decrease ?“Answers of the car manufacturers: The number of ECUs will decrease does not mean: The functionality given by electronics will decrease!
Means:Number of ECUs may decrease in order to
Manage the complex electronic systemReduce the number of failure sourcesMake the system more reliableLimit the cost
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Automotive Electronics Roadmap Design Requirements for Automotive Reliability
Components with Electronic
System-Integration
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Networking of ECUs
Networking of Cars and Environment
1980 1990
Automotive Electronics
2000 2010
Safety, Environment, Fun & Comfort
Digital Systems, Integration, Networking
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Design Requirements for Automotive Reliability
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Automotive Electronics
In-car orsmall distance
Cell Phone
Broadcast (terrestr.)Satellite Broadcast
Networking with Environment
BluetoothW-LAN
GSM/UTMSModule
CarRadioModuleServices
platform
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Design Requirements for Automotive Reliability
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Automotive Electronics
The next big step: „The sensitive vehicle“
Combination ofintelligent surroundsensors with activeand passivesafety systems
Contribution to reducefatalities by 50% (EU e-safety goal)
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Design Requirements for Automotive Reliability
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Automotive Electronics
Integrated Vision System: Applications NightVision
Lane Detection
Object Detection Road Sign Recognition
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Design Requirements for Automotive Reliability
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Automotive Electronics
Challenges for Automotive Electronics
Convergence of Systems- new functions often require networking of different systems- systems accessible from outside (wireless)- need to integrate subsystems of different suppliers
How to keep vehicles – despite their increasing electronics content –affordable for the consumer ?
How to assure extended lifetime reliability and availability of the vehicles despite the underlying very complex electronic systems ?
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Automotive Electronics
Design Requirements for Automotive Reliability
Industrial
-10°C 70°C
5-10 years
environment
<< 1%
conditional
up to 5 years
Automotive
-40°C 85/155°C
up to 15 years
0% up to 100%
target: zero failure
true
up to 30 years
Consumer
0°C 40°C
1-3 years
low
< 10%
none
none
Requirements on Automotive Semiconductors
Parameter
temperature
operation time
humidity
tolerated fieldfailure rates
documentation
supply
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Increasing Temperature Requirements
150
Am
bien
t Tem
pera
ture
50
Automotive
Consumer
125°C
20041996 2012
C°
1992 2000 2008
Drivers:
rising temperatures under the hood
rising power dissipationof microcontrollers
rising control units‘ loads
higher component integration into smallerpackages
more applications indifficult locations
Design Requirements for Automotive Reliability
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Automotive Electronics
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1995 2005 2010
Silicon insideof the actuators
Tj < 210°C
0
500
1000
1500
2000
2500
3000
oper
atin
g lif
e tim
e (h
)
130 150 170 190 210temperature (°C)
Silicon separateof the actuators
Tj < 150°C
Silicon adjacentto the actuators
Tj < 175°C
Design Requirements for Automotive Reliability
Temperature requirements for automotive semiconductors
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Automotive Electronics
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Operating Conditions for Automotive Control Units
20
40
60
0 20 40 60 80
Env
ironm
enta
l Tem
pera
ture
PCB
PCB on Metal µ Hybrid
application
80
100
120
°C
140
160
EM
PECU
ABS/ESP
EPS
TC
Design Requirements for Automotive Reliability
Potential
EM
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Peak Acceleration g(Sinus)
Automotive Electronics
EM = Engine Management, TC = Transmission Control,EPS = Electrical Power Steering, PECU = Pump Electronic Control Unit
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Intelligent Actuator: Control Unit for Electrical Power Steering (EPS)
Design Requirements for Automotive Reliability
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Features:
Compact designusing automotive specificLTCC and DBC technologiestemperatures up to 125°Ccurrent up to 100 A mounting direct at the steering gearacceleration (shock) up to 40 g
Automotive Electronics
26
Design Requirements for Automotive Reliability
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
Outline
Journey from Yesterdays Vision to Today’s World
Requirements for Future Systems
Expected Market Trends
Reliability Trends
Impact on Power Semiconductor
Summary
27
Design Requirements for Automotive Reliability
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
1976 1978 19801982 1984 19861988 1990 19921994 1996 19982000 2002
Lambda Sens. ABS Airbag Navigation E-GAS
Diesel DI Xenon ESP BDE Climate Control%
Automotive Electronics: Installation Rates (WEU)
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Automotive Electronics
Automotive Electronic Sales by Region
10
20
30
40
50
60
70
Bill
ions
of D
olla
rsDesign Requirements for Automotive Reliability
30.1
37.039.6
43.245.9
48.851.9
55.659.6
64.0
'03 '04 '05 '06 '07 '08 '09 '10 '11 '12
Part of Total CAGR2003 2012 ‘03/’12
Asia/Pac 12% 21% 12.3%
Europe 36% 39% 7.8%
Japan 25% 21% 4.1%
Americas 27% 19% 4.9%
World total 7.1%
Source: Bosch
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Automotive Electronics
Automotive Semiconductor Sales by Region
Design Requirements for Automotive Reliability
13,7
17,018,4
20,422,1
24,126,2
28,631,3
34,2
5
10
15
20
25
30
35
40
Bill
ions
of D
olla
rs
'03 '04 '05 '06 '07 '08 '09 '10 '11 '12
Part of Total CAGR2003 2012 ‘03/’12
Asia/Pac 8% 22% 14.9%
Europe 39% 41% 9.8%
Japan 19% 18% 5.8%
Americas 34% 19% 6.5%
World total 9.6%
Source: Bosch
30
Design Requirements for Automotive Reliability
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
Outline
Journey from Yesterdays Vision to Today‘s World
Requirements for Future Systems
Expected Market Trends
Reliability Trends
Impact on Power Semiconductor
Summary
31
Design Requirements for Automotive Reliability
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
Reliability RequirementsReliability = (1 - probability of a failure) per electronic device- at 0 km- in the field over a given period of time
Increasing realibility demands due to higher usage of electronicdevices in vehicles
Car industry requirement:
For each ECU: 0-km and field failure rates < 10 ppm/year
Derived requirement:
for each component: 0-km and field failure rates < 1 ppm/year
32
Design Requirements for Automotive Reliability
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
How to reach reliability against early failuresAssignment and control of ppm limits for each step of the value creation chain:
Assignment and control of ppm limits for each electronic component depending on its complexity
Agreement with all suppliers about ppm limits
Application of systematic in-process quality assurance measures throughout the value creation chain
Intensive “quality mindset” training of all employees
Tight control of failure rate development - regularly followed with high management attention
33
Breakdown of ECU ppm reliability requirementsDesign Requirements for Automotive Reliability
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Automotive Electronics
ECU -failure
faulty design/SW „Mass production failure“
/ bad materialElectronic
components (EC)ECU plant Logistics
EC mech..+EC-Logistics
0
0
10
3
7
0
µC ASIC Flash R MLCCInductors...0,5 0,2 0,02 0 00,1
ASIC0,2
(simplified, example values)
7
0-Defect will be the game of the future. And this will be judged by the
customer only.
34
Design Requirements for Automotive Reliability
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Automotive Electronics
Reliability against Aging Failures:Operating Conditions of Automotive Electronics
Thermal: operating temperature rangenumber and stroke of temperature cycles over lifetime
Mechanical:vibration load – peak mechanical accelerations
Climate/Environment:humidity and corrosive substances (salt, fluids, vapors…)
Σ vehicle application dependent
35
Design Requirements for Automotive Reliability
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Automotive Electronics
Systematic Design for ReliabilityDefinition of technology, design and components for the application
(1) Describe known failure mechanisms bymathematical models using parametersfrom prior end-of-life testing
(2) Determine the real-life, applicationspecific “load profiles” from vehicletesting
(3) Simulate the field reliabilityusing the failure models (1) andthe real-life load profiles (2)
Verification of technology, design and components for the application
(4) Define (shortened) release test profilesusing physical failure models (1) andapplication load profiles (2)
(5) Perform release testing forconfirmation of the life-timereliability of the design
(6) Do additional end-of-life testingfor further design confirmationand verification / improvementof failure models.
36
Design Requirements for Automotive Reliability
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
Outline
Journey from Yesterdays Vision to Today’s World
Requirements for Future Systems
Expected Market Trends
Reliability Trends
Impact on Power Semiconductor
Summary
37 AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
Design Requirements for Automotive Reliability
Die Kraft der Luft
Wiper
Injectors
Active ValveAdjustment
Active Steering
MirrowAdjustment
Seat Position Control
Window Lifter
ActiveSuspension
ConvertibleRoof
Rear WindowDefroster
SunroofAir Condition
Throttle regulation
Adaptive Front Light
Fan Control
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Design Requirements for Automotive Reliability
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
Impact on Power Semiconductors
Power Semiconductors are used in safety critical applications(i. e.: x-by-wire)
RequiredContinuous control of parameters, that show critical operation conditions:voltage, current, temperatureOn site / attached control logic to ensure safe operation
39
Design Requirements for Automotive Reliability
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Automotive Electronics
µC +Speicher
Peripherie Perip
herie
StellerSensoren
Sign
al-
Auf
bere
itung
µC +Speicher
Peripherie Perip
herie
StellerSensoren
Sign
al-
Auf
bere
itung
µC +Memory
Peripherals
Bus Bus
Actuator
Power
Control
Domain based systems architecture
Sensor
Sign
al-
Con
ditio
ning
standard components
Intelligent SatelliteSensors
Intelligent Satellite
Actuators
Central Domain ECU
Inter Domain Bus
automotive specific semiconductor solutions (ASSP, SoC, ASIC, MEMS)
Peripherals
40
Design Requirements for Automotive Reliability
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Automotive Electronics
Control Circuitry in High End Ignitor (SoC)
B
CurrentControl
Over voltageFlag
Driver-Stage
OverheatProtection
Voltageclamping
C
E
Vfl
OverheatLimiter
CurrentFlag
Ifl
41
Current Regulator and TolerancesDesign Requirements for Automotive Reliability
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Automotive Electronics
Standard Solution Current Regulator:
2. Signal Processing• Offset• CMRR (Common Mode Rejection Ratio)• Gain• Anti Aliasing Filter (Nyquist –Criteria)
3. A/D Converter• Quantization Error/ Noise• Gain Error due to Reference
1. Shunt• Tolerance %• Tolerance Tk
4. Controller• Quantization Error
actual Value
Set Value
T1
Load
Signalprocessing
U+
µc
A/DConverter
DriverUnit
Reference
Udiff
Ucm
RShunt
Udiff + CMMR * Ucm
42
CG208: Fully integrated Low Side Current RegulatorDesign Requirements for Automotive Reliability
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Automotive Electronics
Application: High precision low cost current regulator for e.g. transmission control valves
Features: • Dual channel current regulator • Temperature monitor • Fully integrated current controllers
• Low Side power switches • Integrated shunts and • Free wheeling diodes
• Current range up to 1,2A • High accuracy (∆I < 1%) • SPI controlled load current • SPI controlled dither ampl. and freq. • SPI controlled loop characteristics • Fault detection and protection (additional load and µc clock monitor)
ASIC Name: CG208 SOP: Jan. 2007 Package: Bare die, TQFP_ePad44 Process: BCD4S
43
Design Requirements for Automotive Reliability
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
Outline
Journey from Yesterdays Vision to Today‘s World
Requirements for Future Systems
Expected Market Trends
Reliability Trends
Impact on Power Semiconductor
Summary
44
Design Requirements for Automotive Reliability
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
Summary
The trend towards more comfort and more safety will continue.Customer expectations and legal requirements will require “fault tolerant” systems.Diagnostic capability will be mandatory for future electronic systems.Intelligent, redundant systems have to be developed.
45
Design Requirements for Automotive Reliability
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
Automotive Electronics
Thank you!