Fundamentals of Automotive
Electronics
International Automotive
Research Centre
University of Warwick
© 2006 IARC
Course structure
1. Embedded Electronic Control Systems and Electronic
Control Units
2. Introduction to Automotive Networks and CAN
networking
3. Automotive Networks – MOST, LIN and FlexRay network
4. Design and Testing of automotive control systems
5. Automotive Diagnostics
6. Lab Session
© 2006 IARC
Session 1 – Embedded Electronic Control Systems 2
Embedded Electronic Control
Systems and Electronic Control
Units
Gunny Dhadyalla
International Automotive Research Centre
University of Warwick
© 2006 IARC
Agenda
Embedded Electronic Control Systems
What is embedded electronic control?
What is it used for?
Why is it so important?
Other types of embedded automotive electronic systems
Electronic Control Units (ECU’s)
Overview of ECU design
Internal components
Environmental Issues
Working in an automotive environment
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Session 1 – Embedded Electronic Control Systems 4
What is embedded electronic control?
“Embedded”
An autonomous self-contained system, requiring no human or user
intervention
Self-reliant, self-starting, re-initialising &/or shut-down
Capable of self-diagnosis, fault detection & reporting
“Electronic”
Usually some form of micro-controller,
Memory (RAM, FLASH),
I/O logic (Digital, Analogue)
Communications interface (CAN, LIN, MOST etc.)
Sensors and actuators
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What is embedded electronic control?
“Control System”
Controls a function or feature of the vehicle
Implements some form of control algorithm
• Closed loop, Open loop.
Micro-controller runs dedicated application software that performs
the control function/algorithm
Actuator
The
Desired State Control system
Controller under
Signal control
Feedback signal
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What is embedded control used for?
Just about everything!
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Embedded control system usage
Engine Management
Emissions control – CARB legislation
Fuel economy (modes of operation - sports, economy)
Vehicle Dynamics
ABS, DSC, adaptive suspension (ride height, sports, comfort)
HDC, Traction control,
Cruise control, ACC
Safety Systems
Air-bag deployment
Obstacle detection
Lane departure warning
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Embedded control system usage
Adaptive Function
Cruise
Control Growth
The vast majority of new technology looks like this:
DSC
Electronic
Lane- Towbar
Remote
Processor keeping
Diagnostics
Sensor Actuator Traction
Software Rear Multi- ISG Control
In Car PC
media Satellite
Radio El. Water
Auto lights
Adaptive Pump
Auto wipers Headlamps
Communication’s Network EM Valves
Surround ACC
Sound IVDC
Telematics E-Connectivity
Adaptive PTC Heater
suspension Steer-by-
Optical Buses Active
Wire
Navigation steering
Security Brake-by-
ABS Adv. Voice Activation Wire
Body Elec. Blind Spot
Instruments Airbag Restraints
Keyless Detection Fuel Cell
Engine Control Transmission Control ESP EPAS Vehicle
1980 1990 2000 2010
CY
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Session 1 – Embedded Electronic Control Systems 9
Typical premium vehicle electrical architecture
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Session 1 – Embedded Electronic Control Systems 10
Why is embedded electronic control so
important?
Automotive industry is probably one of the fastest
growing in terms of technology introduction.
Enormous industry pressures
To deliver innovation and higher levels of features
• To meet rising customer expectations
• Improve competitiveness (features as selling points)
To reduce development costs and timescales (time-to-market)
• Technology re-use, re-configurable ECU’s
Adapt to new markets.
• Software-only updates and adaptations for new market sectors
Maintain or improve levels of customer satisfaction and loyalty
• Improved reliability, diagnostics & servicing
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Why is embedded electronic control so
important?
Most new features deployed through the use of
distributed electronic control systems.
New features reliant on electronics & software.
Electronics and Software components are becoming an
increasing proportion of the vehicle’s value.
Electronics & software now accounts typically for 40% (and rising) of
the value of a premium vehicle
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Other types of automotive electronic systems
Body (or Chassis) Electronics
Security & immobilisation
Comfort and Convenience
Auto-lights/wipers
Electric Seats,
Passive entry, Key-less Start
Basic Systems
Lights, wipers, windows
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Other types of automotive electronic systems
Infotainment systems
Audio and Multi-media systems
• Radio, CD/DVD, MP3, TV, Satellite Navigation etc.
Communication systems
• Phone, Bluetooth, Wireless networking, Mobile office etc.
• Vehicle-to-vehicle, vehicle-to-infrastructure
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Other types of automotive electronic systems
Human Machine Interaction (HMI)
Controls, displays & touch screens for user input & feedback
Voice recognition
Audio feedback (bings/bongs, spoken)
Haptic feedback (touch/feel feedback)
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Session 1 – Embedded Electronic Control Systems 15
Life is never simple…..
Functionality achieved increasingly via distributed control
systems
Coordinated action of multiple control systems
Examples of distributed cooperative functions - ACC, DSC, Traction
control, park-heat/vent etc.
This leads to increased system complexity
Rising system interactions and dependencies
Rising integration and testing complexity
Rising diagnostic complexity
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Session 1 – Embedded Electronic Control Systems 16
Increasing system complexity – an illustration
Input 1 Out 1
2 binary inputs means 4 test cases
Input 2
(00, 01, 10, 11)
10 binary inputs = 1024 test
cases.
15 binary inputs = 32,768
20 binary inputs = 1,048,756
If inputs represent a range of values
(e.g. speed, temperature) then
number of test cases becomes
unfeasibly large – cannot rely upon
traditional testing methods alone.
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Session 1 – Embedded Electronic Control Systems 17
Typical premium vehicle electrical architecture
600-700 I/O pins
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Session 1 – Embedded Electronic Control Systems 18
Embedded Control Systems - Summary
Used to control a wide range of automotive features &
functions
Implemented using electronics and software
Provide many advantages
Increasing proportion of overall value – most new
features deployed using embedded control systems
Increasing system complexity
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Session 1 – Embedded Electronic Control Systems 19
Electronic Control Units (ECU’s)
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Session 1 – Embedded Electronic Control Systems 20
Electronic Control Unit (ECU) Overview
ECU is the generic term for automotive electronic control
units
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Session 1 – Embedded Electronic Control Systems 21
ECU Types
ECU’s are usually bespoke
Designed specifically for a particular task or application e.g. ECM,
PAM, DSC
Physical design, hardware & software dimensioning are tailored
specifically to requirements of application
Powertrain
High performance, “hard” real-time requirements
Example – control of an engine @ 7,000rpm
Example – Dynamic stability control @ 150mph
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ECU Types
Body Systems
Medium-low performance requirements, “soft” real-time
requirements
Example – control of a window lift
Example – lighting controls
Infotainment Systems
Usually high performance (bandwidth),
• Many audio sugnals (CD/radio/Phone/Nav/Voice activation/DVD etc.)
“reduced” real-time requirements
Example – time to select a radio preset
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Types of ECU’s
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Session 1 – Embedded Electronic Control Systems 24
What’s inside an ECU?
Similar architecture to a typical
ECU PC or laptop, but note:
Application Software There is no external disk
There is no external CD/DVD
Function Diagnostics Drive
There is no keyboard, mouse,
Application Programme Interfaces or monitor
Base Software Components
Hardware
Components &
interfaces
Hardware
Connector
Power Supply Hardwired I/O
Data Network
ECU
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ECU
ECU Building Blocks Application Software
Function Diagnostics
Hardware Application Programme Interfaces
Base Software
Processor (8,16,32-bit, 10,16,32Mhz) Components
Memory (RAM, ROM/FLASH) Hardware
Input & Output logic Connector
• Switches, sensors Hardwired I/O
Data Network
• Digital and analogue
• High current drivers for switching/controlling motors
& actuators
Communications interfaces “physical layer”
• CAN – Controller Area Network (electrical)
• LIN – Local Interconnect Network (electrical)
• MOST – Media Orientated Systems Transport (optical)
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Session 1 – Embedded Electronic Control Systems 26
ECU hardware – basic architecture
Micro-controller RAM FLASH
Analogue Digital Power
Communications
I/O I/O interface management
© 2006 IARC External connector
Session 1 – Embedded Electronic Control Systems 27
Example – Engine Control Module (ECM)
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Session 1 – Embedded Electronic Control Systems 28
Electronic Control Unit (ECU) block diagram
ECU
Application Software
Function Diagnostics
Application Programming Interface Base Software
Components
Base Software Components
Hardware
Connector
Power Supply Hardwired I/O
Data Network
ECU
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Session 1 – Embedded Electronic Control Systems 29
ECU
ECU Building Blocks Application Software
Base Software Components Function Diagnostics
Bootloader API
• A standalone program which allows Base Software
download and replacement of software Components
within the ECU Hardware
Connector
Real Time Operating System (RTOS)
• Provides services and support to higher level application(s)
• Deterministic, pre-emptive, defined performance characteristics
• Schedulers, task lists, message queue handling, resource management
• Communications and Network Management
API - Application Programming Interface
• Provides interface between base software and high level application
• Isolates/protects application software from hardware specifics
• Potential for hardware agnostic applications
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Session 1 – Embedded Electronic Control Systems 30
Electronic Control Unit (ECU) block diagram
ECU
Application
Application Software Software
Function Diagnostics
Application Programming Interface
Base Software Components
Hardware
Connector
Power Supply Hardwired I/O
Data Network
ECU
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Session 1 – Embedded Electronic Control Systems 31
ECU
ECU Building Blocks Application Software
Function Diagnostics
Application Software API
Base Software
Delivers the feature or function Components
• Executes the control function Hardware
• Provides required functionality Connector
Diagnostics
• Provides built in diagnostic modes and services
• Controlled/secure access to ECU fault information
• Self-test, periodic checking of system resources
• Logging of errors (DTC’S) and supporting diagnostic information
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Session 1 – Embedded Electronic Control Systems 32
Electronic Control Unit (ECU) block diagram
ECU
Application Software
Function Diagnostics
Application Programming Interface
Base Software Components
General
Electrical
Hardware
Standards Connector
Power Supply Hardwired I/O
Data Network
ECU
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Session 1 – Embedded Electronic Control Systems 33
Environmental considerations
ECU operates in an automotive environment
Such environments are very harsh
Temperature: -40oC to +85oC (+120oC under bonnet), Dashboard –
solar loading
Physical - vibration, dust, oil
Electrical disturbances
ECU must be able to cope with the electrical environment it
will encounter when working in a vehicle
General Electrical Requirements
• Voltage range, Quiescent current
Electro Magnetic Compatibility (EMC)
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Session 1 – Embedded Electronic Control Systems 34
General Electrical Requirements
Voltage ranges (12V systems):
Immunity to Power Cycling (Cranking)
Immunity to Voltage Offset (Ground shifts)
Immunity to Voltage Dropout (Sporadic, Battery recovery)
Immunity to Voltage Overstress (-14v, 19v, 24v)
• Reverse -14v for 60Secs
• Over-voltage 19V for 1hr, 24V for 60Secs
Electro Static Discharge
Quiescent current:
ECU current drawn when vehicle is parked < 100uA
Attention to wake up modes (especially if activates other parts of
vehicle)
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Session 1 – Embedded Electronic Control Systems 35
A real crank waveform
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Session 1 – Embedded Electronic Control Systems 36
Electro Magnetic Compatibility (EMC)
Emissions
Radiated RF (Noise from vehicle e.g. Ignition system)
Conducted RF (Noise radiated on component power lines)
Conducted Transient (Transient spikes generated on component power lines)
Immunity
RF (Immunity from external interference e.g. cell phones)
Magnetic Field (Immunity from noise of magnetic sensors)
Coupled Immunity (Immunity from transients coupled through wiring)
Continuous Disturbances (Immunity from charging system ripple)
Transient Disturbances
• Switch off of inductive loads
• Load Dump (sudden disconnection of electrical load from alternator) 60V
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Session 1 – Embedded Electronic Control Systems 37
Some other factors
Safety and Legal requirements
Failure to meet even minor legal requirements can result in a major
recall e.g. indicator flash rate
Some ECU’s now perform functions that are safety-critical
Safety critical ECU’s must be developed according to
particular guidelines to ensure:
It is inherently safe under all circumstances
Has fail-safe operation in the event of a fault (e.g. limp-home modes)
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Session 1 – Embedded Electronic Control Systems 38
Review of what we’ve learnt
Embedded Electronic Control Systems
What is embedded electronic control
What is it used for
Why is it so important
Other types of embedded automotive electronic systems
Electronic Control Units (ECU’s)
Basic internal structure and components
Environmental issues
© 2006 IARC
Session 1 – Embedded Electronic Control Systems 39
