Electronics Technologies and Trends in Automotive fieldnpkauto.com/oldweb/data/notes/Classic...

Torino, June 12, 2008

D. AlberoDiesel & Hybrids Controls & Software Dept.FPT R&T

Electronics Technologies and Trends in Automotive field

Automotive Forum 2008 2June 12, 2008

Agenda

Automotive Today NeedsAutomotive Today Needs

Technology Solutions in Electronics Field: HighlightsTechnology Solutions in Electronics Field: Highlights

PowertrainPowertrain: Key Technologies and Electronics Trends: Key Technologies and Electronics Trends

Software ChallengesSoftware Challenges


AutomotiveAutomotive TodayToday NeedsNeeds


Automotive Today Needs

Safety and Safety and ReliabilityReliability

InnovationInnovation ((newnew functionsfunctions and and servicesservices))

EnvironmentalEnvironmental carecare

FuelFuel ConsumptionConsumption ReductionReduction

ComfortComfort

CostCost ReductionReduction at the at the samesame qualityquality levellevel


TechnologyTechnology SolutionsSolutions inin ElectronicsElectronics FieldField::

HighlightsHighlights


Technology Solutions: Highlights

DrivingDriving AssistanceAssistance and Safetyand Safety

IntelligentIntelligent Parking AssistParking Assist

Fiat-Valeo, 844 (New Lancia), 2008Q4

Lane Lane WarningWarning//KeepingKeeping

IVECO, Stralis, since 2006Fiat-TRW, 844 (New Lancia), 2008Q4

Ultrasonic systems•C-MOS based systems•Electric Steering Systems



DrivingDriving AssistanceAssistance and Safetyand Safety

Side AssistSide Assist CollisionCollision MitigationMitigation

•C-MOS based systems•24 GHz short range radar

•3D C-MOS based systems•77 GHz long range radar•Laser scanner



ChassisChassis

RegenerativeRegenerative BrakingBraking BlueBlue & Me& Me

FIA, 60 kW systems, 2009

Kinetic Energy Recovery Systems(KERS)

InfotainmentInfotainment &Telematics&Telematics

Fiat-Microsoft, Grande Punto, since 2006

Nomadic Devices

Integration


Centralized Architecture or Distributed Architecture?

On going debate among Vehicle Manufacturers for a Centralized vs a Decentralized Architecture

•Bugs and Failures are isolated

•Spreads processing demand around vehicle

•Customers do not pay for systems/functions they do

not want•Increases modularity and

scalability (options)

•Cost effective•Saves spaces and weight

•Reduces failures and bugs

•Reduces number of suppliers for OEMs

•Simplifies tuning stage

CentralizedCentralized DistributedDistributed


Domain-related interconnected architecture

ECU 2 ECU 3ECU 1

Gateway1 Gateway2

ECU 2 ECU 3ECU 1

ECU 2 ECU 3ECU 1

Gateway3Backbone Backbone

Domain 1

Domain 2

Domain 3

Interconnections among automotive functional domainsare more effective than traditional overloaded networks.Every domain can use a dedicated network protocol, in order to fulfill ad-hoc needs (e.i. CAN, FlexRay, MOST, LIN, etc.)A backbone communication can link all network together, to exchange data between systems.

ApplicationApplication DomainsDomains


PowertrainPowertrain: Key Technologies and: Key Technologies and ElectronicsElectronics TrendsTrends


What have Electronics enabled to do till now? “Fuel consumption reduction”

Increased average fueleconomyReduced emissions(Carbon Monoxide (CO), Hydrocarbon (HC), Nitrogen Oxides (NOx), particulates (PM))A new car today is about30 times cleaner than a new car in the early 80’s

Source: Strategy Analitics

Fuel consumption trendsFuel consumption trends


Emission targets – “A world wide challenge”

European emission Standards are, today, mainly focused to improveEuropean cities air quality and to improve fuel economy.In order to achieve above mentioned goals, OEMs are developing innovative technologies to meet emission target without penalizing performance and consumptions

NOxNOx and PM and PM emissionsemissions


Diesel NOx Reduction – Low Temperature Combustion Tech.

The reduction of in-cylinder NOx formation throughlower combustion temperature is the most cost-effectiveapproach for passenger cars.


Diesel Soot and NOx Reduction – Premixed Combustion

FundamentalsFundamentals


Diesel Soot and NOx Reduction – Premixed Combustion Control

An internal chamber pressure sensor is needed.ECU acquires and filters internal chamber pressure signal.ECU calculates the 50% of Mass Burnt Fraction (50%MBF, the barycenter of combustion) in real-time, and regulates the injections accordingly.


Gasoline performance and driveability needs – “Fun-to-drive”

A focus on torque increasing at low rpm, instead of the enhancementof power at high rpm

ECU MULTIAIR

Φ1 Φ2

Gestione Solenoid Valves

Camera diAlta Pressione

Solenoid Valve(ON-OFF)

Modulodi Attuazione

Valvola(Pistone + Freno

+ Punteria Idraulica)

Pompante

Accumulatore Olio

Asse a camme(Aspirazione + Scarico)

Bilancierea Basso Attrito

RICHIESTACOPPIA

Combustibile Accensione

Aria

ATTUATOREELETTRO-IDRAULICO

UNIAIR

MultiairMultiair TechnologyTechnology forfor GasolineGasoline


Global Engine Trend – “2005 - 2015”

Source: Frost & Sullivan

““In 2015 the 68% In 2015 the 68% ofof sold sold vehiclesvehicles estimatedestimated toto runrun GasolineGasoline, 26% Diesel, and 6% Hybrid , 26% Diesel, and 6% Hybrid VehiclesVehicles””


Hybrids and Alternative Fuel

FIAT produces CNG vehicles since 2000 (Multipla, Punto, Panda)IVECO focuses on Diesel Hybrids (Daily)Hydrogen and Fuel Cell not usable technology until now for high production cost and difficulties in distribution

Micro Hybrid: Micro Hybrid: Stop&StartStop&Start usingusing anan integratedintegrated starter starter generatorgenerator

Source: Robert Bosch Corp.

Full Hybrid:Full Hybrid: IC IC EngineEngine + + electricalelectrical motormotor


New safety requirements – “IEC61508 and new ISO 26262”

Today there is not a safety standard the automotive industry willcomply with.Anyway, legally the industry has to comply at least with what isconsidered the “state of technology”IEC61508 standard is considered the state of technology, so automotive industry has to refer to it.A new safety standard, expecially applicable to automotive systems, will arrive soon: ISO 26262. Engine control is considered safety-relevant.


ISO 26262 – “Functional Safety”

Functional Safety is part of the overall safety that depends on a system or equipment operating correctly in response to its inputs. (IEC TR 61508-0, September 2005). It is the Absence ofunacceptable risk due to hazards caused by mal-functionalbehaviour of E/E systems.

“Correctly” with regard to:Specification, implementation or realization errors failure during operation periodreasonably foreseeable operational errorsreasonable foreseeable misuse

ISO 26262 addresses hazards caused by safety related E/E systems due to malfunctions, excluding nominal performances of active and passive safety systems

ISO 26262 adopts a customer risk-based approach for the determination of the risks at vehicle level, provides automotive-specific analysis methods to identify the safety integrity level(ASIL) associated with each undesired effects, which ASIL establishes product process and methods tailoring


ISO 26262 - Product Development Process

Concept phaseConcept phase Production andProduction andoperationoperation

Initiating SW development

SW safety requirements specification

SW architecture and design

SW implementation

SW unit test

SW integration and test

SW safety acceptance test

HW requirements analysisHW architecture design

Quantitative requirements for random HW failures

Measures for avoidance and control of systematic HW failures

Qualification of parts and components

Initiation(new development,

derivative, change, …)

Product development systemProduct development system

Product development SWProduct development SWProduct development HWProduct development HW

Overall requirements for HW-SW interface

Safety HW integration and verification

System design(HW / SW reqs

allocation, ASIL decomposition, …)

Specification of technical safety concept

(Measure with associated system reactions, redundancy

items independence, …)

Functional safety assessment

Integration& Test Hazard analysis and

risk assessment (ASIL identification)

Functional safety Concept

(warnings, redundancies, degradation, …)

Production

Operation, service and decommissioning


Dual core platforms: “Twice the Brain without the Drain”*

Multicore architecture: Two or more independentprocessors into a single package, often a single integrated circuitMulticore solution allows to boost overallperformance, without applying clock speedincreasing, that implies power consumption and heatgeneration, which forces expensive cooled packaging.Tests on dual-core MCU in some PC applications haveshown that same performance can be achieved by a dual core MCU at 200 MHz with respect to a single core MCU at 500 MHz.In particular in Powertrain applications, the faster clock requires faster memories, which does not fulfill costrequirements due to the power consumption and the working ambient temperature range needs (from-40 degC to 125/150 degC).Moreover, Multicore architecture enables the parallelism for Safety requirements

*By FreescaleTM Semiconductor

Source: Infineon Technologies

Source: Freescale Semiconductors


Software challenges: Parallel Programming Model

Two basic techniques:Co-processor approach: one core designed as the master (runs the OS, manages data, executes program), the others compute a task in a reserved data set. Sync via interrupt or another sync mechanism.

Multi-process OSMultiple instances (each core has own OS)• Ideal for Safety Applications• Expensive for OS licenses costs

Single instance (only one OS)• Suitable for fully distributed process• Overhead for intra-core comm. and sync• Not recommended for Safety

Tools:Tools for automatic CPU load balancing are required. To maximizeparallelism benefits the Application split and the resources sharingtechniques are to be developed. Powertrain application deployment has to face re-validation effort as a rearrangement of the partition may influence the whole system design.


Software challenges: complexity management, quality increasing, reducing time

Model-based approach to develop control functions

Verification along all software development process: software requirements verificationsoftware design verificationunit testingstatic analysis, testing formal methodsintegration testingverification testing in labverification testing in engine benchverification testing in vehicle


Software challenges: Formal Methods integration in SW development process

Formal methods (FM) refer to mathematically rigorous techniques and tools for the specification, design and verification of software and hardware systems. Software for complex applications requires a more mathematical approach.Formal methods can introduce greater rigor and improve SW development process, but in industry software engineering community are not fully convinced of their usefulness.The first reason is that FM are difficult to understand: the mathematics of FM is based on notations and concepts not familiar to end-users.The second reason is that only one notation does not fit and does not address all aspects of a whole complex system. A combination of methods is required.FM classification includes:

Formal specificationFormal developmentFormal verification


Formal verification using Abstract Interpretation

Verifying software artifacts in early stage of the process saves time and costs!

Design Coding Unit Test

Integration Test

AIanalysis

Verification Test

C programming language, widely used to develop software for critical on-board embedded systems, is modeled by means of a mathematical theory (semantics) in such a way the execution of the related program can be virtualized and its behavior can be predicted. The Abstract Interpretation (AI) represents the software analysis, related to the previous model, able to simulate the software dynamic behavior, without executing it, in order to find run-time errors at the source code level, before the executable verification stages.

Detected run-time errors include non-initialized variables, access conflicts for unprotected shared data in multi-thread applications, invalid arithmetic operations, out of bounds for array access and pointers, illegal type conversion, overflow/underflow, unreachable code.


Thank you for your kind attention!Thank you for your kind attention!

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