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Torino, June 12, 2008
D. Albero
Diesel & Hybrids Controls & Software Dept.FPT R&T
Electronics Technologies and Trends in Automotive field
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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
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AutomotiveAutomotive TodayToday NeedsNeeds
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Automotive Forum 2008 4June 12, 2008
Automotive Today Needs
Safety andSafety and ReliabilityReliability
InnovationInnovation ((newnew functionsfunctions andand servicesservices))
EnvironmentalEnvironmental carecare
FuelFuel ConsumptionConsumption ReductionReduction
ComfortComfort
CostCost ReductionReduction at theat the samesame qualityquality levellevel
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Automotive Forum 2008 5June 12, 2008
TechnologyTechnology SolutionsSolutions inin
ElectronicsElectronics FieldField::
HighlightsHighlights
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Technology Solutions: Highlights
DrivingDriving AssistanceAssistance and Safetyand SafetyIntelligentIntelligent Parking AssistParking Assist
Fiat-Valeo, 844 (New Lancia), 2008Q4
LaneLane WarningWarning//KeepingKeeping
IVECO, Stralis, since 2006
Fiat-TRW, 844 (New Lancia), 2008Q4
Ultrasonic systemsC-MOS based systems
Electric Steering Systems
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Technology Solutions: Highlights
DrivingDriving AssistanceAssistance and Safetyand SafetySide 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
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Centralized Architecture or Distributed Architecture?
On going debate among Vehicle Manufacturers for a Centralized vs aDecentralized Architecture
Bugs and Failures areisolated
Spreads processingdemand around vehicle
Customers do not pay forsystems/functions they do
not want
Increases modularity andscalability (options)
Cost effective
Saves spaces and weightReduces failures and
bugs
Reduces number ofsuppliers for OEMs
Simplifies tuning stage
CentralizedCentralized DistributedDistributed
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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 amongautomotive functional domainsare more effective than traditionaloverloaded networks.
Every domain can use a dedicatednetwork protocol, in order to fulfillad-hoc needs (e.i. CAN, FlexRay,MOST, LIN, etc.)
A backbone communication canlink all network together, to
exchange data between systems.
ApplicationApplication DomainsDomains
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PowertrainPowertrain: Key Technologies and: Key Technologies and
ElectronicsElectronics TrendsTrends
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What have Electronics enabled to do till now?Fuel consumption reduction
Increased average fueleconomy
Reduced 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 80s
Source: Strategy Analitics
Fuel consumption trendsFuel consumption trends
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Emission targets A world wide challenge
European emission Standards are,today, mainly focused to improveEuropean cities air quality and toimprove fuel economy.
In order to achieve above mentionedgoals, OEMs are developinginnovative technologies to meetemission target without penalizingperformance and consumptions
NOxNOx and PMand PM emissionsemissions
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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.
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Diesel Soot and NOx Reduction Premixed Combustion
FundamentalsFundamentals
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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 theinjections accordingly.
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Global Engine Trend 2005 - 2015
Source: Frost & Sullivan
In 2015 the 68%In 2015 the 68% ofof soldsold vehiclesvehicles estimatedestimated toto runrunGasolineGasoline, 26% Diesel, and 6% Hybrid, 26% Diesel, and 6% Hybrid VehiclesVehicles
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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 highproduction cost and difficulties in distribution
Micro Hybrid:Micro Hybrid: Stop&StartStop&Start
usingusing anan integratedintegrated starterstartergeneratorgenerator
Source: Robert Bosch Corp.
Full Hybrid:Full Hybrid: ICIC EngineEngine ++ electricalelectrical motormotor
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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 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.
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ISO 26262 Functional Safety
Functional Safety is part of the overall safety that depends on asystem 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 period reasonably foreseeable operational errors reasonable foreseeable misuse
ISO 26262 addresses hazards caused by safety related E/Esystems due to malfunctions, excluding nominal performances ofactive and passive safety systems
ISO 26262 adopts a customer risk-based approach for thedetermination of the risks at vehicle level, provides automotive-specific analysis methods to identify the safety integrity level(ASIL) associated with each undesired effects, which ASILestablishes product process and methods tailoring
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Automotive Forum 2008 26June 12, 2008
ISO 26262 - Product Development Process
Concept phaseConcept phase Production andProduction andoperationoperation
Initiating SW development
SW safety requirementsspecification
SW architecture and design
SW implementation
SW unit test
SW integration and test
SW safety acceptance test
HW requirements analysis
HW architecture design
Quantitative requirementsfor random HW failures
Measures for avoidanceand control of systematicHW failures
Qualification of partsand components
Initiation
(new development,derivative, change, )
Product development systemProduct development system
Product development SWProduct development SWProduct development HWProduct development HW
Overall requirementsfor HW-SW interface
Safety HW integrationand verification
System design
(HW / SW reqsallocation, ASIL
decomposition, )
Specification of technicalsafety concept
(Measure with associatedsystem reactions, redundancy
items independence, )
Functional safetyassessment
Integration& TestHazard analysis and
risk assessment(ASIL identification)
Functional safetyConcept
(warnings,redundancies,
degradation, )
Production
Operation, service anddecommissioning
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Dual core platforms: Twice the Brain without the Drain*
Multicore architecture: Two or more independentprocessors into a single package, often a singleintegrated circuit
Multicore solution allows to boost overallperformance, without applying clock speed
increasing, that implies power consumption and heatgeneration, which forces expensive cooled packaging. Tests on dual-core MCU in some PC applications have
shown that same performance can be achieved by adual core MCU at 200 MHz with respect to a singlecore MCU at 500 MHz.
In particular in Powertrain applications, the faster clockrequires faster memories, which does not fulfill costrequirements due to the power consumption and theworking ambient temperature range needs (from-40 degC to 125/150 degC).
Moreover, Multicore architecture enables theparallelism for Safety requirements
*By FreescaleTM Semiconductor
Source: Infineon Technologies
Source: Freescale Semiconductors
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Automotive Forum 2008 29June 12, 2008
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 areserved data set. Sync via interrupt or another sync mechanism.
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:
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.
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Automotive Forum 2008 30June 12, 2008
Software challenges: 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
S f h ll F l M h d i i i SW d l
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Automotive Forum 2008 31June 12, 2008
Software challenges: Formal Methods integration in SW developmentprocess
Formal methods (FM) refer to mathematically rigoroustechniques and tools for the specification, design andverification of software and hardware systems.
Software for complex applications requires a moremathematical approach.
Formal methods can introduce greater rigor and improveSW development process, but in industry softwareengineering community are not fully convinced of theirusefulness.
The first reason is that FM are difficult to understand: the
mathematics of FM is based on notations and concepts notfamiliar to end-users. The second reason is that only one notation does not fit
and does not address all aspects of a whole complexsystem. A combination of methods is required.
FM classification includes: Formal specification Formal development Formal verification
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Automotive Forum 2008 32June 12, 2008
Formal verification using Abstract Interpretation
Verifying software artifacts in early stage of the process saves time and costs!
Design CodingUnitTest
IntegrationTest
AIanalysis
VerificationTest
C programming language, widely used to develop software for criticalon-board embedded systems, is modeled by means of a mathematicaltheory (semantics) in such a way the execution of the related programcan be virtualized and its behavior can be predicted. The AbstractInterpretation (AI) represents the software analysis, related to theprevious model, able to simulate the software dynamic behavior, withoutexecuting 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, accessconflicts for unprotected shared data in multi-thread applications, invalidarithmetic operations, out of bounds for array access and pointers,illegal type conversion, overflow/underflow, unreachable code.
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Thank you for your kind attention!Thank you for your kind attention!