Electronics Technologies and Trends in Automotive field

D. Albero
Diesel & Hybrids Controls & Software Dept.
FPT R&T

Torino, June 12, 2008

Agenda

Automotive Today Needs

Technology Solutions in Electronics Field: Highlights

Powertrain: Key Technologies and Electronics Trends

Software Challenges

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 Automotive Today Needs

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Automotive Today Needs

Safety and Reliability

Innovation (new functions and services)

Environmental care

Fuel Consumption Reduction

Comfort

Cost Reduction at the same quality level

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 Technology Solutions in
Electronics Field:
Highlights

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Technology Solutions: Highlights

Driving Assistance and Safety

Intelligent Parking Assist Lane Warning/Keeping

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

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

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Technology Solutions: Highlights

Driving Assistance and Safety

Side Assist Collision Mitigation

•3D C-MOS based systems

•77 GHz long range radar
•C-MOS based systems
•Laser scanner
•24 GHz short range radar

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Technology Solutions: Highlights

Chassis Infotainment &Telematics

Regenerative Braking Blue & Me

FIA, 60 kW systems, 2009 Fiat-Microsoft, Grande Punto, since 2006

Kinetic Energy Recovery Systems Nomadic

Devices
(KERS)
Integration

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 Centralized Architecture or Distributed Architecture?

On going debate among Vehicle Manufacturers for a Centralized vs a

Decentralized Architecture

Centralized Distributed

•Bugs and Failures are

•Cost effective isolated
•Saves spaces and weight •Spreads processing
demand around vehicle
•Reduces failures and
bugs •Customers do not pay for
systems/functions they do
•Reduces number of
not want
suppliers for OEMs
•Increases modularity and
•Simplifies tuning stage
scalability (options)

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Domain-related interconnected architecture

Application Domains
Interconnections among
automotive functional domains
are 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.

ECU 1 ECU 2 ECU 3 ECU 1 ECU 2 ECU 3

Domain 1 Domain 3
Backbone Backbone
Gateway1 Gateway2 Gateway3
Domain 2

ECU 1 ECU 2 ECU 3

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 Powertrain: Key Technologies and
Electronics Trends

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

Fuel consumption trends

Increased average fuel

economy
Reduced emissions
(Carbon Monoxide (CO),
Hydrocarbon (HC),
Nitrogen Oxides (NOx),
particulates (PM))
A new car today is about
30 times cleaner than a
new car in the early 80’s

Source: Strategy Analitics

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Emission targets – “A world wide challenge”

NOx and PM emissions European emission Standards are,

today, mainly focused to improve
European 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

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Diesel NOx Reduction – Low Temperature Combustion Tech.

The reduction of in-cylinder NOx formation through

lower combustion temperature is the most cost-effective
approach for passenger cars.

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Diesel Soot and NOx Reduction – Premixed Combustion

Fundamentals

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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.

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

Multiair Technology for Gasoline

ATTUATORE
ELETTRO-IDRAULICO
RICHIESTA
COPPIA ECU MULTIAIR Solenoid Valve Accumulatore Olio UNIAIR
(ON-OFF)
Gestione Solenoid Valves Pompante
Bilanciere
Aria a Basso Attrito

Φ1 Φ2 Camera di
Alta Pressione
Asse a camme
Modulo (Aspirazione + Scarico)
di Attuazione
Valvola
(Pistone + Freno
+ Punteria Idraulica)

Combustibile Accensione

A focus on torque increasing at low rpm, instead of the enhancement

of power at high rpm

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Global Engine Trend – “2005 - 2015”

“In 2015 the 68% of sold vehicles estimated to run

Gasoline, 26% Diesel, and 6% Hybrid Vehicles”

Source: Frost & Sullivan

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Hybrids and Alternative Fuel

Micro Hybrid: Stop&Start Full Hybrid: IC Engine + electrical motor

using an integrated starter
generator

Source: Robert Bosch Corp.

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

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New safety requirements – “IEC61508 and new ISO 26262”

Today there is not a safety standard the automotive industry will

comply with.
Anyway, legally the industry has to comply at least with what is
considered 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.

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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 of
unacceptable risk due to hazards caused by mal-functional
behaviour of E/E systems.

“Correctly” with regard to:

f Specification, implementation or realization errors
f failure during operation period
f reasonably foreseeable operational errors
f reasonable 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

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ISO 26262 - Product Development Process

Concept phase Product development system Production and

Specification of technical
operation
Functional safety
safety concept assessment
(Measure with associated
Initiation system reactions, redundancy
items independence, …) Production
(new development,
derivative, change, …)
System design
(HW / SW reqs Integration
Hazard analysis and allocation, ASIL & Test
risk assessment decomposition, …) Operation, service and
(ASIL identification) decommissioning

Product development HW Product development SW

Functional safety
Concept HW requirements analysis Initiating SW development

(warnings, HW architecture design

SW safety requirements
redundancies, Quantitative requirements specification
for random HW failures
degradation, …) Measures for avoidance SW architecture and design
and control of systematic
HW failures
SW implementation
Safety HW integration
and verification
SW unit test
Qualification of parts
and components SW integration and test
Overall requirements
for HW-SW interface SW safety acceptance test

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

Multicore architecture: Two or more independent

processors into a single package, often a single
integrated circuit
Multicore solution allows to boost overall
performance, without applying clock speed
increasing, that implies power consumption and heat
generation, which forces expensive cooled packaging.
Tests on dual-core MCU in some PC applications have
shown that same performance can be achieved by a
dual core MCU at 200 MHz with respect to a single Source: Freescale Semiconductors
core MCU at 500 MHz.
In particular in Powertrain applications, the faster clock
requires faster memories, which does not fulfill cost
requirements 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
Source: Infineon Technologies

*By FreescaleTM Semiconductor

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Software challenges: Parallel Programming Model

Two basic techniques:

f 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.

f Multi-process OS
… Multiple 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:
f Tools for automatic CPU load balancing are required. To maximize
parallelism benefits the Application split and the resources sharing
techniques are to be developed.
f Powertrain application deployment has to face re-validation effort as a
rearrangement of the partition may influence the whole system design.

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Software challenges: complexity management, quality increasing,
reducing time

Model-based approach to develop control functions

Verification along all software development process:

f software requirements verification
f software design verification
f unit testing
f static analysis,
f testing formal methods
f integration testing
f verification testing in lab
f verification testing in engine bench
f verification testing in vehicle

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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:
f Formal specification
f Formal development
f Formal verification

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Formal verification using Abstract Interpretation

AI Unit Integration Verification

Design Coding
analysis Test Test 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.

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

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 Thank you for your kind attention!

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