EH2175A. Main Microprocessor Infineon Aurix TC MHz 4M Flash 472K SRAM Float Point Capability Dual Core Safety Check V Operating Voltage

Transcription

1 EH2175A Main Microprocessor Infineon Aurix TC MHz 4M Flash 472K SRAM Float Point Capability Dual Core Safety Check Inputs 15 Analog Inputs 20 Digital Inputs 2 Frequency Inputs 1 Wake-up Input 9-16 V Operating Voltage Communication 4 CAN 2.0B 1 FlexRay 1 LIN Sensor 5v Supply: 9 channels Environmental -40 C to +85 C Operating ISO16750 Compliant Simulink Model Based Design Outputs 10 High-Side Drivers 26 Low Side Drivers (10 of which could be configured as PWM outputs)

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 Mechanical Dimensions... 8 CHAPTER 3 PINOUTS... 9 Connector... 9 Pinouts System Example CHAPTER 4 APPLICATION NOTES Power VCU Power DRVP Sensor Power Supply VPWR Control Logic Inputs Digital Inputs Analog Inputs Frequency Inputs Outputs Low Side Outputs High Side Outputs Communication Module

4 VCU CAN Module Introduction DBC File population CCP Protocol Implementation Safety Monitoring Module Three-Level Safety Monitoring Architecture Controller Chip-Level Diagnosis Software Architecture CHAPTER 5 SOFTWARE TOOLS Code Generation Tool EcoCoder Calibration Tool EcoCal Re-Programming Tool EcoFlash APPENDIX: STANDARD TESTS 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 of an electric or hybrid vehicle. VCU receives 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, runs fault diagnosis and determines the overall vehicle drivability. VCU is the master of the vehicle control network, or CAN bus-based network. VCU Features ISO26262 Oriented Design ASIL-D Safety Level EH2175A VCU has an Infineon TriCore TC275 microcontroller on board. Two of three independent 32-bit TriCore CPUs are used for a redundant hardware design, and a 3-level safety monitoring software is implemented to meet the ASIL-D safety standards, while at the same time maximize the performance. *Please refer to Infineon official file AURIX TC275T/TC277T Product Brief Basic Software (BSW) Model Based Design Production Code Generation Tool CAN Bus-Based Programming Ecotrons VCU comes with the Basic Software (BSW) pre-programmed, 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 DC 12V(9~16V) Working temperature -40~85 C Humidity 0~95%, no condensation Storage temperature -40~85 C Protection level IP67 Mechanical shock 50g Expected life 10 years Electric performance ISO16750, ISO7637 compliance EMC CISPR25 compliance Dimensions mm Weight 600g Housing Die-casting aluminum 7

8 Mechanical Dimensions Unit: mm 8

9 Chapter 3 Connector and Pinouts Connector 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 manufacturer 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 DC 12V power, AI 28 VCU ground Voltage range: 9-16V *See page 16 for application note DRVP PGND 119 Power of HSOs, LSOs 120 with PWM function V2_1 16 5V2_2 22 5V2_3 38 5V3_1 19 5V3_2 35 5V3_3 41 5V4_1 53 5V4_2 56 5V4_3 59 GND DRVP ground 5V sensor supply Sensor ground Maximum current: 100mA Voltage supply: 5V±2% *See page 18 for application note 10

11 81 GND Sensor ground KEYON 24 VCU key switch, AI 27 WAKEUP 27 Wake-up input CAN A_H 64 CAN A_H CAN A_L 65 CAN A_L CAN B_H 25 CAN B_H CAN B_L 26 CAN B_L CAN C_H 7 CAN C_H CAN C_L 8 CAN C_L CAN D_H 45 CAN D_H CAN D_L 46 CAN D_L LIN1 9 LINBUS FlexRay_P 63 FlexRay_P FlexRay_N 44 FlexRay_N AI01 15 AI02 18 AI03 21 AI04 34 AI05 37 Analog inputs AI06 40 AI08 55 AI09 58 AI07 52 AI11 61 Analog inputs AI12 73 Active-high: 5V Voltage range: 0-12V *See page 19 for application note Active-high: 6V Voltage range: 0-12V Built-in 120 Ω terminal resistor No terminal resistor No terminal resistor No terminal resistor A/D resolution: 12bit Input voltage range: 0-5V A/D resolution: 12bit Input voltage range: 0-5V Pull-up resistor: 10K *See page 21 for application note 11

12 AI13 75 I14 77 AI15 79 AI16 43 DI01 33 DI02 11 DI03 70 DI04 50 DI05 14 DI06 69 DI07 32 DI08 49 DI09 48 DI10 13 DI11 31 DI12 68 DI13 67 DI14 47 DI15 29 DI16 10 DI17 28 DI18 12 DI19 30 DI00 66 DI_G 72 SPEED1 71 SPEED2 51 HSO HSO Analog inputs Analog input ignition position #3 (start) Digital inputs Digital inputs Digital input 00 INTERLOCK INPUT Ground INTERLOCK OUTPUT Frequency inputs High-side drivers A/D resolution: 12bit Input voltage range: 0-5V Pull-up resistor: 10K A/D resolution: 12bit Voltage range: 0-16V Dividing resistor: 22K Active-low: 2V Input voltage range: 0-5V Active-high: 4V Input voltage range: 0-12V *See page 20 for application note *See page 20 for application note VCU ground with RC filter circuit. Resolution: 0.1Hz Input frequency range: 15Hz 10kHz *See page 23 for application note 12

13 HSO HSO A continuous *See page 25 for application note HSO05 82 HSO06 90 HSO07 98 HSO HSO09 62 HSO10 2 LSO LSO LSO LSO LSO LSO LSO LSO LSO LSO10 95 LSO LSO12 87 LSO13 84 LSO14 92 LSO15 91 LSO16 83 LSO LSO LSO23 85 LSO24 93 LSO LSO High-side drivers Low-side drivers Low-side drivers Low-side drivers PWM outputs 0.5A continuous 2A continuous 1A continuous 0.5A continuous *See page 24 for application note 0.2A continuous Output frequency range: 15Hz 2kHz *See page 24 for application note 13

14 LSO27 99 LSO LSO29 94 LSO

15 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. 15

16 Chapter 4 Application Notes 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 0-16V with 12 bits resolution. Read ADC Volt block in EcoCoder could be used to read voltage of BATT, please refer to 0-16V Analog Voltage Input part of section for block setting details. Example Diagram 16

17 DRVP DRVP pins are the power supply for HSOs, LSOs with PWM function. Connect the V+ to the DRVP input (Pin 119 and 120) and the V- to PGND (Pin 96, 97, 88, 89). For over-current protection, fuses with proper rating are recommended for DRVP power supply. Example Diagram 17

18 Sensor Power Supply The EH2175A provides 9 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 18

19 VPWR Control Logic With BATT connected, VCU Power (VPWR) could be activated by KEYON, WAKEUP, FlexRay Wake, CAN Wake and Power Delay signal. KEYON, WAKEUP are hardwire wake-up inputs with actual pins on the VCU connector. They are active-high. KEYON is a typical key switch input. WAKEUP could be used for some application that needs to wake up VCU. For example, to wake up the vehicle when charger is plugged in. CAN Wake and FlexRay Wake are two wake-up signals controlled by the communication bus drivers. The drivers constantly monitor CAN or FlexRay bus and could activate VPWR when there is certain traffic detected on the bus. 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). 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: WAKEUP and KEYON inputs need to be low-asserted. Make sure there is no data traffic on CANA/FlexRay bus. Lastly trigger the EcoCoder power-down block. Notice: It is recommended to connect KEYON (Pin 24) to the actual vehicle key switch and use the Power Management Example block in EcoCoder to manage the VCU and vehicle shutdown process. Proved power management strategies are integrated in that block. 19

20 Inputs Digital Inputs The digital inputs on EH2175A 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 input voltage is 4 V, the EcoCoder block will read the input as 1. Active-low: EcoCoder block will read a default value of 1; When the input voltage is 2 V, the EcoCoder block will read the input as 0. Example Diagram 20

21 Analog Inputs Analog Input Wiring Example EH2175A offers 14 analog inputs with 12bits resolution. Voltage input range is 0-5V. 0-5V Analog Inputs 0-5V analog inputs are capable of both resistance and voltage type inputs Resistance Input Example: Voltage Input Example: 21

22 0-16V Analog Inputs Dividing resistors are used for 0-16V analog inputs. AI16, 27, 28 are the three analog input channels that can measure 0-16V input. Analog input channel AI28 is internally connected to BATT for VCU power supply voltage measurement. It is of 12 bits resolution. Analog input channel AI27 is internally connected to KEYON for switch signal measurement. It is of 12 bits resolution. Analog input channel AI16 is recommended to connect to the actual vehicle ignition switch for engine cranking. It is of 12 bits resolution. Voltage Input Example: 0-16V analog voltage inputs have a voltage ratio of ( ) / 22 as indicated by the picture above. Select Custom Voltage Ratio of Input Type in EcoCoder block. 22

23 Frequency Inputs This VCU provides 2 PWM frequency input channels with pull-up resistors by default. The maximum resolution for frequency measurement could be configured to 0.1Hz. The measurable frequency range is 15Hz-10kHz. Example Diagram 23

24 Outputs Low Side Outputs 6 channels x 2A continuous current, LSO 01, 02, 03, 04, 05, channels x 1A continuous current, LSO 07, 08, 09, 10, 11, channels x 0.5A continuous current, LSO 13, 14, 15, PWM outputs x 0.2A continuous current. LSO 21, 22, 23, 24, 25, 26, 27, 28, 29, 30. Example Diagram Channel Number LSO LSO LSO21-30 Output shorted to V + Output shorted to GND Open load Output shorted to V + Output shorted to GND Open load Over load Over temperature Output shorted to V + Output shorted to GND Open load Over load Over temperature Diagnostic Method 24

25 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. 4 channels (HSO 01-04) x 2A continuous. 6 channel (HSO 05-10) X 0.5A continuous. High Side Outputs Wiring Example High Side Outputs Driver Diagnostic Channel Number HSO01-04 HSO05-10 Output shorted to V + Output shorted to GND Open load Output shorted to V + Output shorted to GND Diagnostic Method This VCU provides 10 channels of PWM outputs. 25

26 Communication Module VCU CAN Module Introduction This VCU provides 4 CAN channels CAN A, CAN B, CAN C, CAN D, all of the four CAN channels are CAN 2.0B high speed type. CAN A has a built-in internal 120Ω terminal resistors, while there is no terminal resistor on CAN B, C, D. CAN A supports VCU wake-up function, the VCU will be woken up by messages on the bus. 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. CAN Node CAN Node 120Ω CANH CANL CANH CANL CANDH Driver CANDL CAN Bus VCU CAN Driver CANCH CANCL PC Driver Driver CAN Bus 120Ω CANAH CANAL CANBH CANBL CAN Bus CANH CANL CANH CANL CANH CANL CANH CANL 120Ω 120Ω 120Ω CAN Node CAN Node CAN Node CAN Node 26

27 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. 27

28 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: 28

29 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 in-house 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. 29

30 Safety Monitoring Module VCU 2175A comes with some advanced safety monitoring design, including independent dual core hardware structure and three-level monitoring software architecture, to meet the system safety level, up to ASIL-D. The TC275 is Infineon 32-bit multi-core MCU and has three independent CPUs on chip (therefore called TriCore ). Of 3 CPUs, two have a monitoring core each, called Checker core. It meets the automotive ISO26262 functional safety requirements, up to ASIL-D level. Overall, there are five cores, three of them are user-programmable, two of them are monitoring cores and nonprogrammable. EH2175A VCU uses the two independent CPUs with monitoring core. Each of two independent CPUs has its own monitoring Checker. There is a 3 rd CPU is reserved, not used. In other words, EH2175 VCU uses 4 cores out of 5 on the TC275 chip. Each main core and monitoring core run in lockstep mode, so they run / execute the same instruction all the time. After executing each instruction, the results of the two cores will be compared. If the result is different, the exception interrupt will be incurred and reported. Independent dual core structure uses CPU0 and CPU1 for software development, each CPU has three-level safety monitoring software running. 30

31 Three-Level Safety Monitoring Architecture Three-level safety monitoring architecture 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. Controller Chip-Level Diagnosis a) Support Flash and Ram diagnostics of the master chip. b) Support kernel self-test diagnostics of the master chip. 31

32 Software Architecture 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 the functions into different services which would be directly called by Simulink blocks in application software. ECU* abstraction layer encapsulates drivers of microprocessor and peripherals. Software and ECU hardware can be 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, power management chip and CAN transceiver. Notice: ECU stands for electronic control unit. VCU is one kind of ECU. 32

33 Chapter 5 Software Tools Function Software Feature Specifically designed Simulink library for Ecotrons hardware One-click code generation process Production Code Generation EcoCoder Commercial compiler integrated HighTec or Tasking Complete model-based design with lower-level software encapsulation, and 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 33

34 Code Generation Tool 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 links 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. 34

35 Calibration Tool 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 user-friendly interfaces. EcoCAL also integrates data logging function, and includes a data analysis tool. It parses the standard A2L files, and manages the calibration data in the format of Mot files. For more details, please refer to EcoCAL User manual. 35

36 Re-Programming Tool EcoFlash EcoFlash is a simple PC based software to program the controller, using CAN bus with a typical CAN-USB adapter. Ecotrons VCU comes with a typical bootloader pre-programmed. The programming uses either the CCP based protocols or UDS based. For more details, please refer to Ecotrons EcoFlash User Manual. Appendix: Standard Tests 36

37 The tables list the standard tests done according to the ISO or SAE standards, by VCU manufacturer or the third party, which is an authorized certification institute. For complete test reports, please Environmental Test Standards Subject 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 Subject 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 Subject Test Standard 37

38 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 ISO ISO ISO ISO ISO NA ISO Average quiescent current 1mA ISO ISO ISO ISO