EV2274A. (SBC) MC33CFS6500 microprocessor

Transcription

1 EV2274A Micro control unit NXP MPC5744 ISO26262 ASIL-D integrity level 200MHz 2.5M Flash 384K SRAM Float Point Capability (SBC) MC33CFS6500 microprocessor Inputs 15 Analog Inputs 21 Digital Inputs 4 Frequency Inputs 3 Wake-up Inputs Outputs 10 High-Side Drivers (2 of which could be configured as PWM outputs) 18 Low Side Drivers (4 of which could be configured as PWM outputs) 9-32V Operating Voltage Communication 3 CAN 2.0B Sensor 5v Supply: 5 channels Environmental Operating temperature: -40 C to +85 C ISO16750 Compliant Simulink Model Based Design

2 Contact us: Web: Address: Beck Road, STE D5, Wixom, Michigan, USA Tel:

3 CONTENTS CHAPTER 1 GENERAL INFORMATION... 5 VCU Introduction... 5 VCU Features... 5 CHAPTER 2 HARDWARE... 7 Specifications... 7 Dimensions... 8 CHAPTER 3 CONNECTOR... 9 Connector Parts... 9 Pinouts System Example CHAPTER 4 FUNCTION DESCRIPTION AND APPLICATION NOTE Power VCU Power Sensor Power Supply VPWR Control Logic Inputs Digital Inputs Analog Inputs Frequency Inputs Outputs Low Side Outputs High Side Outputs Communication Module VCU CAN Module Introduction DBC File Import CCP Protocol Implementation Safety Monitoring Module

4 Software Architecture CHAPTER 5 SOFTWARE COMPATIBILITY Prototype/Production Code Generation EcoCoder Powerful Calibration Software EcoCAL VCU Programming Tool EcoFlash APPENDIX: TEST STANDARD Environmental Test Standards EMC Test Standards Electrical Performance Tests Standards

5 Chapter 1 General Information VCU Introduction Vehicle Control Unit, or VCU, is the master controller for an electric or hybrid vehicle. VCU receives the sensors and driver input signals, including pedal inputs, vehicle speed signals, and other inputs, manages the system energy, commands the driver demanded torque to powertrain, coordinates vehicle components, achieves fault diagnose and determines the overall vehicle drivability. VCU plays a critical and supervisory role in the vehicle control network, or CAN bus-based network. VCU Features ISO26262 Oriented Design ASIL-D Safety Level EV2274A has NXP 5744 automotive level microcontroller on board. NXP 5744 is built around a safety concept based on delayed lock step mechanism, targeting an ISO26262 ASIL-D integrity level. *Please refer to NXP official file Safety Manual for MPC5744P Basic Software (BSW) Model Based Design Production Code Generation Tool CAN Bus-Based Programming Ecotrons VCU comes with the basic/low-level software, supporting all typical input/output drivers for vehicle controls. The BSW is encapsulated as Simulink library block sets, called EcoCoder. Users could take advantage of the model-based design to quickly build control strategy within Simulink. With one-click in Simulink, you can get the executable code and A2L description file. EcoFlash is a CAN bus-based programming tool. Users could re-program the executable into VCU conveniently. 5

6 CAN Calibration Protocol (CCP) Ecotrons VCU supports the in-house calibration tool, EcoCAL, and also can be compatible with INCA, CANape, or other CCP-based calibration tools. 6

7 Chapter 2 Hardware Specifications Supply voltage Working temperature Humidity Storage temperature Protection level Mechanical shock Expected life Electric performance EMC Dimensions Weight Housing DC 12V/24V(9~32V) -40~85 C 0~95%, no condensation -40~85 C IP67 50g 10 years ISO16750, ISO7637 compliance CISPR25 compliance mm 600g Die-casting aluminum 7

8 Dimensions Unit: mm 8

9 Chapter 3 Connector Connector Parts Ecotrons VCUs use the automotive rated connector, made by Tyco Electronics, which meets the automotive safety requirements. The following table lists parts of the connector. Customers can buy their own connector parts to make the harness, or they can ask Ecotrons to buy for them. No. Name Part Number Supplier 1 CONN HEADER 122POS R/A TIN TE 2 CONN PLUG HOUSING 81POS JPT TE 3 MQS REC 40P ASSY TE 4 Contact Crimp Socket AWG Tin TE 5 Contact Crimp Socket AWG Tin TE 6 MQS 81P LEVER(R) ASSY TE 7 MQS 40P LEVER(L) ASSY TE 8 MQS RETAINER HSG FOR 81P TE 9 MQS RETAINER HSG FOR 40P TE 9

10 Pinouts Name Pin # Description Specification BATT GND V2 51 5V3 41 5V4 49 5V5 69 5V6 6 GND DC 12/24 V power Voltage range: 9-32V VCU ground 5V sensor supply Sensor ground KEYON 59 Key switch DI22 81 VCU wake-up input DI21 40 VCU wake-up input CANA_SHIELD 58 CAN A Shielding CANB_SHIELD 77 CAN B Shielding CAN A_H 56 CAN A_H CAN A_L 55 CAN A_L Maximum current: 50mA Voltage supply: 5V±2% Active-high: 8V Voltage range: 0-36V *See page 15 for application note *See page 16 for application note *See page 17 for application note Built-in 120 Ω terminal resistor CAN B_H 57 CAN B_H No terminal resistor 10

11 CAN B_L 76 CAN B_L CAN C_H 54 CAN C_H CAN C_L 73 CAN C_L LIN1 78 LINBUS AI03 16 AI04 35 AI05 17 AI09 71 AI11 24 AI16 22 AI18 23 AI20 72 AI06 36 AI07 18 AI08 37 AI12 62 AI15 20 AI17 79 AI19 61 DI07 43 DI10 65 DI13 26 DI15 45 DI16 63 DI17 67 DI18 68 DI01 42 DI02 52 DI03 53 DI04 38 Analog inputs Analog inputs Analog inputs Digital inputs Digital inputs Built-in 120 Ω terminal resistor Not support but could be added upon request A/D resolution: 12bit Input voltage range: 0-36V Dividing resistor: 3.48K *See page 21 for application note A/D resolution: 12bit Input voltage range: 0-5V Pull-up resistor: 10K *See page 19 for application note A/D Resolution: 12bit Input voltage range: 0-5V Active-high: 8.5V Input voltage range: 0-24V *See page 19 for application note *See page 18 for application note Active-low: 5V Input voltage range: 0-24V *See page 18 for application note 11

12 DI12 21 DI08 31 DI09 25 SPEED1 64 SPEED2 47 SPEED3 66 SPEED4 8 HSO HSO HSO06 98 HSO HSO04 99 HSO HSO08 86 HSO14 85 HSO07 94 HSO LSO01 95 LSO06 96 LSO LSO08 89 LSO LSO LSO13 88 LSO03 90 LSO17 93 LSO18 92 LSO19 91 LSO LSO Frequency inputs High-side drivers High-side drivers High-side drivers High-side drivers Low-side drivers Low-side drivers Low-side drivers Input frequency range: 1Hz 5kHz Can be configured as digital inputs in EcoCoder *See page 22 for application note 0.5A rated, peak current 1A *See page 24 for application note 1A rated, peak current 3A 1A rated, peak current 3A Can be configured as PWM outputs (20Hz 1KHz) 3A rated, peak current 5A 0.5A rated, peak current 1A *See page 23 for application note 0.5A rated, peak current 1A Can be configured as PWM outputs (20Hz 1KHz) 1A rated, peak current 3A 12

13 LSO LSO LSO LSO LSO Low-side drivers Low-side drivers 1A rated, peak current 3A 3A rated, peak current 5A EV2274A Datasheet_V1.3 13

14 System Example This simple system diagram provides a sample application for VCU hardware resource. It only illustrates the some typical connections. The full wiring connection is to be defined for specific user applications. DI21, 22 integrate VCU wake-up function by default, also are able to read digital input signals. 14

15 Chapter 4 Function Description and Application Note Power VCU Power Always connect all available power supply pins to allow maximum current capability, because each 12V power pin only allows limited current through. To avoid current overload on certain pins, and to avoid the potential damage, all power pins should be connected even they seem to be redundant. The total current through VCU is as maximum 15A. Analog input channel AI28 is internally connected to BATT for VCU power supply voltage measurement. Its input voltage range is 0-36V with 12 bits resolution. Read ADC Volt block in EcoCoder could help read voltage of BATT, please refer to 0-36V Analog Voltage Input part of section for block setting details. Example Diagram 15

16 Sensor Power Supply EV2274A provides five channels of 5V sensor power supply. 5V sensor ground is common grounded internally with VCU power ground. Sensor ground should connect to VCU signal ground instead of vehicle chassis ground. Example Diagram 16

17 VPWR Control Logic With BATT connected, VCU Power (VPWR) could be activated by KEYON, DI21, DI22, CAN Wake and Power Delay signal. Power Delay signal is controlled by the low level software and it is used for VCU powerdown delay. This delay function provides the power to the VCU for an extended time window after the user turning off the key-switch. During this extended time, or after-run, VCU could do some house-keeping work, such as storing the critical data into non-volatile memory (NVM). CAN Wake is a wake-up signal controlled by corresponding communication bus driver. The driver constantly monitors CAN bus and would activate VPWR when there is traffic detected on the bus. KEYON, DI21, DI22 are wake-up inputs with actual pins on the VCU connector, KEYON is a typical key switch input and DI21 and DI22 are digital inputs. They are active-high and could be used as wake-up signal inputs for some applications that need to wake up VCU. For example, to wake up vehicle when charger detected. The user application software shall, before initiating the VCU shutdown process, make sure all the wake-up signals mentioned above are not keeping the VCU awake: DI21/DI22 and KEYON all need to be low-asserted. Make sure there is no traffic on CAN bus. Notice: It is recommended to connect KEYON (Pin 59) to the actual vehicle key switch and use the Power Management Example block to manage the VCU and vehicle shutdown process. Proved power management strategies are integrated in that block. 17

18 Inputs Digital Inputs The digital inputs on EV2274A can be used to read the state of a digital input which shares ground reference with VCU. There are two kinds of inputs: Active-high: EcoCoder block will read a default value of 0; When the channel reads a voltage 8.5 V, the EcoCoder block will read the input as 1. Active-low: EcoCoder block will read a default value of 1; When the channel reads a voltage 5 V, the EcoCoder block will read the input as 0. SPEED 1, 2, 3, 4 could be configured in EcoCoder to be digital inputs. DI21, 22 integrate VCU wake-up function by default. Please refer to section for detail. Property Channel # Description DI 07, 10, 13, 15, 16, 17, 18, 21, 22, 31*, Active-high 32* Active-low DI 01, 02, 03, 04, 08, 09, 12, 33*, 34* * SPEED 1, 2 could be configured as DI 31, 32 respectively * SPEED 3, 4 could be configured as DI 33, 34 respectively Example Diagram 18

19 Analog Inputs EV2274A offers 15 analog inputs with 12bits resolution. There are two types of input signal voltage range, 0-5V and 0-36V. Resolution Voltage Range Channel # Description 12bits 0-5 V AI 06, 07, 08, 12, 15, 17, V AI 03, 04, 05, 09, 11, 16, 18, 20 Analog Input Wiring Example 0-5V Analog Inputs For 0-5V analog inputs, AI 06 and 07 have internal pull up 5V supply for resistance input. The rest of 0-5V analog inputs are of voltage input type. Pull-Up Resistor Value(Ohm) 10k AI 06, bit Resolution Channels(0-5V) Resistance Input Example: 19

20 Voltage Input Example: 0-36V Analog Voltage Inputs Dividing resistors are used for 0-36V analog inputs. Voltage Input Example: For 0-36V analog input, users need to specify Custom Voltage Ratio in the following EcoCoder block to help application software read correct voltage input, the ratio is ( ) /

21 Frequency Inputs EV2274 provides 4 PWM frequency input channels. SPEED1 and SPEED2 have pull-down resistors by default, while SPEED3 and SPEED4 have pull-up resistors. The maximum resolution for period measurement is 1Hz The measurable frequency range is 1Hz-5kHz. SPEED 1, 2, 3, 4 could be configured in EcoCoder as digital inputs. Example Diagram 21

22 Outputs Low Side Outputs EV2274A provides 18 low side outputs with overcurrent and overvoltage protection. These drivers could be used as Boolean outputs for driving peripheral devices such as relays, pumps, etc. 11 channels x 500mA continuous current, IC driver with load status (open circuit/short circuit) feedback and diagnostic function. 5 channels (LSO 02, 04, 09, 11, 15) x 1A continuous current 2 channels (LSO 14, 16) x 3A continuous current LSO03, 17, 18, 19 can be configured as PWM outputs. They could generate 20Hz 1kHz square wave PWM signals with resolution of 1Hz. Example Diagram Channel Number LSO 01, 02, 04, 06, 07, 08, 09, 10, 11, 12, 13, 14, 15, 16 LSO 03, 17, 18, 19 Output shorted to V + Output shorted to GND Open load Over load Over temperature Output shorted to V + Output shorted to GND Over load Over temperature Diagnostic Method 22

23 High Side Outputs This VCU provides 10 high side outputs with overcurrent and overvoltage protection. These drivers could be used as Boolean outputs for driving peripheral devices such as relays, pumps, etc. 3 channels (HSO 01, 02, 06) x 500mA continuous low-current, IC based driver with load status (open circuit/short circuit) feedback and diagnostic function. 5 channels (HSO 03, 04, 05, 08, 14) x 1A continuous current 2 channels (HSO 07, 10) x 3A continuous current HSO08, HSO14 can be configured as PWM outputs. They could output 20Hz 1KHz square wave PWM signals with resolution of 1Hz. High Side Outputs Wiring Example High Side Outputs Driver Diagnostic Channel Number All HSOs Output shorted to V + Output shorted to GND Open load Over load Over temperature Diagnostic Method 23

24 The power supply of LSOs and HSOs can be controlled by EcoCoder block Power Control Output. The boolean input signal to the block determines whether LSOs and HSOs receive power. Communication Module VCU CAN Module Introduction This VCU provides 3 CAN channels CAN A, CAN B, CAN C, all of the CAN channels are CAN 2.0B high speed type. CAN A, CAN C have built-in 120Ω terminal resistors, while there is no terminal resistor on CAN B. CAN A and CAN B support VCU wake-up function, the VCU could be woken up by any messages on CAN A and messages with user specified ID on CAN B. For example, after the KEYON goes to low, which initiates the VCU to sleep, the VCU will be woken up as soon as there are messages on CAN A. This function could be used for situation where VCU need to be turned on for certain applications, such as vehicle charging. 24

25 Driver 120Ω CANCH CANCL PC Driver Driver CAN Bus 120Ω CANAH CANAL CANBH CANBL CAN Bus CANH CANL CANH CANL 120Ω CAN Node CAN Node CANH CANL CANH CANL 120Ω CAN Node CAN Node CAN Implementation Layers (1) Driver layer: the data link layer of communication model, including the IO driver and CAN drive of the microcontroller. (2) Abstraction layer: the network layer of communication model. It is responsible for choosing corresponding IOs, providing CAN channel initialization, CAN sender/receiver interface for the service layer. (3) Service layer: the interactive layer of communication model. The implementation of this layer is based on the interface function provided by the abstraction layer and achieved with the Simulink model and s-function. (4) Application layer: with DBC file and customer s Simulink model, specific CAN communication setup based on user-defined parameters could be implemented in this layer. 25

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27 DBC File Import The implementation of CAN messages in the application software can utilize the DBC file which specifies formats and scaling of the CAN messages and signals already. In many cases, the DBC file is existing and full of CAN signals, and it saves a lot of work for users simply import the DBC file into the Simulink models, and populate the CAN messages. Ecotrons provides a convenient way to convert the.dbc file to.m file and then populate the Simulink models. The procedure is shown as below: 27

28 CCP Protocol Implementation CCP service, DAQ definition and storage page configuration are implemented in low level software; while the station address, DTO ID, CRO ID and other basic parameters can be configured in the s-function. Ecotrons VCU supports CCP-based online calibration, the VCU is compatible with EcoCAL, the Ecotrons own calibration software, and other CCP-based calibration software such as INCA. For more information about our calibration software EcoCAL, please refer to the EcoCAL User s Manual. 28

29 Safety Monitoring Module In EV2274A, the checker core and the fault collection and control unit (FCCU) in the main microcontroller NXP MPC5744P, together with the Fail-safe Machine in SBC FS6500, establish a master-slave architecture to realize the safety monitoring function. The safety monitoring function could be abstracted as a 3-level structure, as shown in the picture below. Level 1: Vehicle control functions, including all vehicle control strategies and fault diagnosis. Level 2: Monitoring level 1 by a redundancy design, level 2 is independent to the Level 1. If there is discrepancy between level 2 and the level 1, level 2 will force the critical safety reaction, such as setting the torque command to Neutral. Level 3: Low level monitoring of the software and hardware. CPU0 and CPU1 will constantly crosscheck each other, if the check fails, it will shut of the actuator/outputs, and avoid hazard situations. 29

30 After VCU received the all the inputs, the input data would be sent to both level 1 and level 2 at the same time, level 1 would send the processed results to level 2, those results would be verified in level 2 and if the verification in level 2 fails, the VCU would cut off the outputs. The main controller is responsible for level 1 and level 2, plus the memory (RAM) monitoring. Whatever process being executed by the main controller will be running in the checker core at the same time and two chips crosscheck each other constantly. When the crosscheck between the checker core and the main controller indicates a faulty result, the FCCU fault mitigation strategy will be triggered, and the fault will be reported to SBC chip at the same time, through FCCU_F[0] and FCCU_F[1], and SBC will cut off the VCU output Software Architecture 30

31 There are two parts of software inside the microcontroller,, application software (ASW) and basic software (BSW). BSW is also called low level software, and it is preloaded into microcontroller by VCU manufacturer. ASW is usually created by the customer in Simulink environment and programmed to VCU via CAN bus tool EcoFlash. BSW consist of three sub layers: Service layer includes system service, memory service and communication service. This layer encapsulates all basic software functions into different service which would be directly called by command in application software. ECU* abstraction layer encapsulates drivers of microprocessor and peripherals. Then, software and ECU hardware are separated. Microprocessor and peripheral driver layer include drivers of microprocessor and peripherals. Typically, microprocessor includes driver of watchdog, timer, SPI, LIN, CAN, ADC, PWM and Flash. Peripheral includes drivers of HSO, LSO, and power management chip and CAN transceiver. Notice: ECU stands for electronic control unit. VCU is a kind of ECU. 31

32 Chapter 5 Software Compatibility Function Software Feature Specifically designed Simulink library for Ecotrons hardware One-click code generation process Prototype/Production Code Generation EcoCoder Commercial compiler integration Code Warrior Complete model-based design with lowerlevel software encapsulation, abstraction Short learning curve For EcoCAL: Calibration and Measurement EcoCAL INCA CANape Powerful calibration tool CCP based Various integrated measurement tools Data logging and analysis VCU Programming EcoFlash CAN bus based programming tool 32

33 Prototype/Production Code Generation EcoCoder EcoCoder is an enhanced auto code generation library added on top of Simulink s generic Embedded Coder. It is specifically designed for Ecotrons hardware and it bridges the Simulink models directly to the target hardware, providing users the capability to generate the production code by ONE CLICK. For more details, please refer to the EcoCoder User Manual. 33

34 Powerful Calibration Software EcoCAL EcoCAL is a professional calibration tool, developed by Ecotrons. It is specifically designed for Ecotrons VCUs. The software is based on the CCP protocol, and uses the CAN bus for data communication with target hardware. It has various measurement tools integrated for different kinds of signals, providing a more user-friendly interface. EcoCAL also integrates data logging function, and provides an integrated data analysis tool. It parses the standard A2L files, and manages the calibration data in the format of S19 files, Mot files or CAL files. For more details, please refer to EcoCAL User manual. 34

35 VCU Programming Tool EcoFlash EcoFlash is a simple PC based software to program the controller, developed by Ecotrons, using CAN communication for programming, with a typical bootloader pre-programmed in the microprocessor. For more details, please refer to Ecotrons EcoFlash User Manual. 35

36 Appendix: Test Standard These tables are extracted from third party test report. For complete report, please Environmental Test Standards Topic Electrical operation during cycling ambient temperature Ambient storage temperature High and low temperature test Thermal shock Humid heat cyclic test Damp heat, steady-state test Dust and particulate Splash test Leakage and function test Corrosion test Fluids and chemicals Mechanical shock / Pot hole test Vibration Drop Test standard ISO ISO ISO ISO ISO ISO IP67 ISO ISO ISO IP66 ISO ISO ISO EMC Test Standards Topic Test requirement Conducted emission test-voltage CISPR 25:2008 method Conducted emission test Current probe CISPR 25:2008 method Radiated emission test-alse method CISPR 25:2008 Bulk current injection ISO :2011 Absorber-lined shielded enclosure ISO :2004 CI on the signal line transient ISO interference Voltage transient emissions test ISO :2011 Signal line transient conducted ISO :2007 immunity test Immunity to magnetic field ISO :2007 Electrical Performance Tests Standards 36

37 Topic Over voltage test Reverse polarity protection test AC voltage superposition test Supply voltage slow down test Voltage transient drop test Reset performance test Starting voltage test Quiescent current measurement test Single - wire open circuit test Multi - line open circuit test Short-circuit protection Insulation resistance Test Standard ISO ISO ISO ISO ISO NA ISO Average quiescent current 1mA ISO ISO ISO ISO