Drivers of Electronics applied to Vehicle and Powertrain
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1 Drivers of Electronics applied to Vehicle and Powertrain D. Albero Head of Diesel & Hybrids Controls & Software Dept. Hybrids Control Systems Program Manager Torino, January 24th, 2008
2 Agenda Automotive Today Needs Research and Technology Solutions in Electronics Field: Highlights Powertrain: Key Technologies and Electronics Trends Hardware Challenges Software Challenges January 24th, 2008 Electronics Forum Automotive 2
3 Automotive Today Needs January 24th, 2008 Electronics Forum Automotive 3
4 Automotive Today Needs Safety and Reliability Innovation (new functions and services) Environmental care Fuel Consumption Reduction Comfort Cost Reduction at the same quality level January 24th, 2008 Electronics Forum Automotive 4
5 Research and Technology Solutions in Electronics Field: Highlights January 24th, 2008 Electronics Forum Automotive 5
6 Research and Technology Solutions: Highlights Driving Assistance and Safety Intelligent Parking Assist Fiat-Valeo, 844 (New Lancia), 2008Q4 Lane Warning/Keeping IVECO, Stralis, since 2006 Fiat-TRW, 844 (New Lancia), 2008Q4 Ultrasonic systems C-MOS based systems Electric Steering Systems January 24th, 2008 Electronics Forum Automotive 6
7 Research and Technology Solutions: Highlights Driving Assistance and Safety Side Assist Collision Mitigation C-MOS based systems 24 GHz short range radar 3D C-MOS based systems 77 GHz long range radar Laser scanner January 24th, 2008 Electronics Forum Automotive 7
8 Research and Technology Solutions: Highlights Chassis Regenerative Braking FIA, 60 kw systems, 2009 Infotainment &Telematics Blue & Me Fiat-Microsoft, Grande Punto, since 2006 Kinetic Energy Recovery Systems (KERS) Nomadic Devices Integration January 24th, 2008 Electronics Forum Automotive 8
9 Centralized Architecture or Distributed Architecture? On going debate among Vehicle Manufacturers for a Centralized vs a Decentralized Architecture Centralized Distributed Cost effective Saves spaces and weight Reduces failures and bugs Reduces number of suppliers for OEMs Simplifies tuning stage 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) January 24th, 2008 Electronics Forum Automotive 9
10 Powertrain: Key Technologies and Electronics Trends January 24th, 2008 Electronics Forum Automotive 10
11 What have Electronics enabled to do till now? Fuel consumption reduction 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 January 24th, 2008 Electronics Forum Automotive 11
12 Emission targets A world wide challenge 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 January 24th, 2008 Electronics Forum Automotive 12
13 New safety requirements IEC61508 and new ISO 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 Engine control is considered safetyrelevant. January 24th, 2008 Electronics Forum Automotive 13
14 PM Reduction Improved Diesel Particulate Filter Cost Reduction Pre-Cat elimination DPF volume reduced Platinum reduced Improved Regeneration Efficiency Shorter regeneration time Less post-injection time Reduced oil dilution January 24th, 2008 Electronics Forum Automotive 14
15 DPF Regeneration Control Basics Control Unit Untreated Exhaust Exhaust Back Pressure Sensor Diesel Particulate Filter Igniter Fuel Supply Air Supply Temperature Sensor Treated Exhaust January 24th, 2008 Electronics Forum Automotive 15
16 NOx Reduction Low Temperature Combustion Technologies The reduction of in-cylinder NOx formation through lower combustion temperature is the most cost-effective approach for passenger cars. January 24th, 2008 Electronics Forum Automotive 16
17 Soot and NOx Reduction Premixed Combustion Fundamentals January 24th, 2008 Electronics Forum Automotive 17
18 Soot and NOx Reduction Premixed Combustion At low BPME (<4 bar) high EGR rates, early injection and a specific injection pattern At medium BPME (>4 bar) a delayed injection is needed. This will lead to a combustion instability: A combustion closed loop control cylinder by cylinder is mandatory January 24th, 2008 Electronics Forum Automotive 18
19 Soot and NOx Reduction Premixed Combustion Control System 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. January 24th, 2008 Electronics Forum Automotive 19
20 Global Engine Trend In 2015 the 68% of sold vehicles estimated to run Gasoline, 26% Diesel, and 6% Hybrid Vehicles Source: Frost & Sullivan January 24th, 2008 Electronics Forum Automotive 20
21 Hybrids and Alternative Fuel Micro Hybrid: Stop&Start using an integrated starter generator Full Hybrid: IC Engine + electrical motor 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 January 24th, 2008 Electronics Forum Automotive 21
22 Vehicle Management Unit VMU: manages the torque split between IC engine and electric motor, and moves the vehicle requesting the actuation of the robotized gearbox accordingly. Manages the vehicle start in Hybrid or Electric mode. Switches off/on the IC engine during running (Stop&Start) Manages the energy flow recharging the batteries (Regeneration Braking) ABS8 Transmission Control System (ESV1) Body Computer (BC) Tachograph Vehicle Data Bus (VDB) - SAE J1939 EOBD Connecto r Diagnostic Connector Vehicle Management Unit (VMU) Electric Servo Steering (EPHS) Engine Control Bus (ECB) - SAE J1939 DIESEL Control System (EDC) INVERTER (ICU) Clutch Control Unit (CCU) Battery Management System (BMS) January 24th, 2008 Electronics Forum Automotive 22
23 Performance and driveability needs Fun-to-drive Multiair Technology for Gasoline RICHIESTA COPPIA ECU MULTIAIR Gestione Solenoid Valves Aria Solenoid Valve (ON-OFF) Accumulatore Olio Pompante ATTUATORE ELETTRO-IDRAULICO UNIAIR Bilanciere a Basso Attrito Φ1 Φ2 Camera di Alta Pressione Modulo di Attuazione Valvola (Pistone + Freno + Punteria Idraulica) Asse a camme (Aspirazione + Scarico) Combustibile Accensione A focus on torque increasing at low rpm, instead of the enhancement of power at high rpm January 24th, 2008 Electronics Forum Automotive 23
24 Increasing system complexity Common rail case January 24th, 2008 Electronics Forum Automotive 24
25 Hardware challenges January 24th, 2008 Electronics Forum Automotive 25
26 Hardware challenge: system complexity and higher performance HW solution: Higher digital and analog I/O, and more power (CPU Mhz) January 24th, 2008 Electronics Forum Automotive 26
27 Components become Systems: System-on-chip January 24th, 2008 Electronics Forum Automotive 27
28 Safety Requirements and number of chips ASIC (Application-Specific Integrated Circuit) ASSP (Application-Specific Standard Product) IC (Integrated Citcuit) In the near future more safety functions will be carried out by less devices January 24th, 2008 Electronics Forum Automotive 28
29 Software Challenges January 24th, 2008 Electronics Forum Automotive 29
30 Software challenge: complexity management, quality increasing, reducing time Model-based approach to develop control functions Verification along all software development process: software requirements verification software design verification unit testing static analysis, testing formal methods integration testing verification testing in lab verification testing in engine bench verification testing in vehicle Verifying software artifacts in early stage of the process saves time and costs! January 24th, 2008 Electronics Forum Automotive 30
31 Standard Software Development Process: V-cycle System Requirements Definition Acceptance Testing Software Requirements Definition Verification Testing Architecture Design Integration Testing Lifecycle Approaches Detailed Design Unit Testing Project Types Incremental Delivery At module level Software Coding Production Projects Advanced Projects Prototypes / Short life Projects January 24th, 2008 Electronics Forum Automotive 31
32 Control Functions Development: model-based approach Control Design Manual Target Implementation Traditional Methods: process split in 2 phases Control Design Software manual implementation Model-based approach Model-based approach Homogeneous design flow Common specification environment and language No paperwork and misinterpretation Simulation and testing of associated software Increased quality, and saved time and costs! January 24th, 2008 Electronics Forum Automotive 32
33 Picture-to-code approach For each block, SW Engineer can control code generation editing a dialog box. Class: block output is generated as variable (RAM) or constant (Flash/Eeprom) Type: choice of C data type, 8/16/32 bit Integer or Floating Point. LSB: for integer data type, variable resolution setting editing Least Significant Bit value January 24th, 2008 Electronics Forum Automotive 33
34 Formal verification using Abstract Interpretation Design Coding AbIES analysis Unit Test Integration Test 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 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! January 24th, 2008 Electronics Forum Automotive 34
35 Testing environments LAN CCP CAN Bus Static Simulation Approach Manual User Inputs Software Repository Development Station In-Circuit Emulator Target Electronic Control Unit Static Simulator...from Real World Dynamic Simulator Dynamic Simulation Approach Mission Profiles Data Base Test Case Data Base Plant Real Time Models January 24th, 2008 Electronics Forum Automotive 35
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