KPIT Cummins. Automotive Body Electronics and Chassis Presentation

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1 KPIT Cummins Automotive Body Electronics and Chassis Presentation

2 Body and Chassis Practice Overview Over 10 years in Body and Chassis 125+ projects 150+ engineers Body and Chassis 25+ OEMs and Tier 1 Customers Full Software Development System Design and Functional Prototyping HIL Testing and Algorithm Development Competence Independent Verification & Validation Maintenance and Feature Enhancement People

3 Body Chassis, Safety and Security Experience Door Control Module, Power window, Power Seat, Power mirror Lift Gate and Luggage Door, HVAC, Light Control, BCM, wiper control, Electric Power Steering Four wheel drive Air suspension and Damping ESC ( Stability Control) ABS Body Chassis Safety Security Airbag Tire pressure Monitor System Keyless and Passive Entry Immobilizer System Passive anti theft 3

4 Body and Chassis Feature Development approach Complete Capability Requirement 1. User Feature / Idea 2. Standardization 3. Legislation Validation Vehicle /HIL Requirement Specification S R S S R S S R S HIL and Vehicle Validation Strategy Design Validation Strategy Development Simulink Model Software Architecture Design Integration On ECU Calibration Tuning Capability For Majority of feature Rapid Prototyping Autocode static void mdlterminate(simstruct *S) {} #if defined(matlab_mex_fil E) Simulink Model and Verification (Model in Loop ) 4 Auto / Manual Coding static void mdlterminate(simstruct *S) {} #if defined(matlab_mex_file) #if defined(matlab_mex_file) #if defined(matlab_mex_file) #if defined(matlab_mex_file) #if defined(matlab_mex_file) Functional Validation (Unit Testing and SIL) Minimal Capability

5 Body Case Studies 5

6 Power Seat Module Software Development Abstract Power Seat Module (PSM) is used to control the Driver and Passenger seat in Car. Seat position can be controlled to desired position using Motor and Hall sensor feedback. This module works along with Door module and remote control which are connected to vehicle network. Overview Seat motor controlling in 4 directions Seat position memorization upto 4 Manual and Auto position control Standard diagnostic services support as per ISO14229 Network Management with CAN communication Fault detection for Input switches, Motor, hall sensors Fault detection and storage as DTC in EEPROM Scope Porting of NOS components PSM Application enhancement Development of Application specific Diagnostic Kernel Validation of PSM on actual seat module Challenges Non-availability of Product hardware during initial phase of project Simulation of Door Module, Remote Control messages using CAPL scripts. Issues with Legacy software. Tools & Technologies Star12D64 Processor, IAR complier Customer specific diagnostic, bootloader tools Metrics 6053 SLOC (Code developed/ modified ) Effort - 23 man months Schedule -15 man months Resources 2 to 4 Engineers 6

7 Power Windows Software Development System Overview Movement of Windows UP and DOWN for Driver, Passenger and Rear Passenger Driver Override and Express DOWN (Un Supervisory) BCM Remote inputs OFF, CRANK and RUN Power modes supported Battery voltage and Current Monitoring through Analogue inputs Battery short and Ground short protection Up and Down Relay Control Wheel/steering angle from BCM module (gateway) Challenges: Code size in 2Kb, 1624 SLOC Software in Assembly Hardware 8 bit controller with 8 Mhz in eval board Application Flash ROM size of 2Kb 128 bytes each of RAM and EEPROM 2 ADCs of 10 bit resolution PBA and PBB I/O of 20 ports WDT at 10 msec Software Switch De bounce algorithm Motor Driver Algorithm A2D Algorithm Calibration settings Diagnostics Scheduler in 10 m Sec loop 7

8 Power Mirror Software Development Abstract The scope of the project is to develop the software to control the Power mirror. The driver shall be able to move the driver and passenger mirror left, Right, Up or Down or even lock using the switches provided in the car. Overview The Power Mirror Switch module is implemented for automated mechanism to move the Right and Left Mirrors in Up/Down/Left/Right directions. The lockout functionality can be used for Power Window. ATMEL ATtiny261 microcontroller is used. Four motors are used to control mirrors. Motors are controlled by a driver IC ATA6836 which is interfaced to ATMEL ATtiny261 microcontroller through SPI communication. Three LEDs are used to represent the choice selected among the Right Mirror Switch, Left Mirror Switch and lockout switch. Challenges The software must be implemented in 1.6Kb of Flash memory. 80 Bytes of EEPROM must be used to store the calibration values with increased lifetime. Tools & Technologies 8bit Atmel micro Motor control IC Assembly language Metrics SLOC: 1143 FLASH: 1572 BYTES (76.8%) RAM: 51 BYTES EEPROM: 18 BYTES Effort PD Schedule 5 man months Resources - 1 to 2 Engineers 8

9 Power Closing Control : Power Lift Gate Overview Lift Gate Door hinged in to vehicle body, the motor system which opens and closes the doors operated by controller which is coupled to detection system. Power lift gate system provides predetermined force to open/close the lift gate depends on obstacle. Scope : Analyse Requirements Implementation of Diagnostic code Unit Testing QAC Analyse Reports Functional testing - Remotely (Develop Test script and Execute and Generate Test reports) OEM: AUDI and Porsche Challenges: Executing the functionality with out physically observing the movement of the power lift gate. Verification of result being carried out only by analyzing the diagnostic results. Configuration of parameters for different vehicle. Tools: Innovator Editor Greenhills Compiler Tessy (Unit Testing tool) QAC Tool Test Automation Script (TAS) NEC V850ES 32-bit Single-Chip Microcontroller 9

10 Wiper Control Software Development Context: Wiper Control Module This module controls the wipers (Front & Rear), This module activates wiper when it receives rain detected information from Rain sensor module and also it activates when it receives information from driver. (Either single wipe or continuous wipe) Scope : Analyse Requirements Verifying the models against requirements and update the model. Auto code Generation and Optimization. Creating test specification from requirement specification. Testing the model in MIL, SIL and PIL with 100% Code coverage. Analyzing and debugging of the failed test case Front Wiper Actuator This identifies if any blockage is detected in wiping path, reports blockage to master module and comes to parking position. Head Lamp wash This module controls the washing of head lamps Challenges: Functional testing using Time Partioning Tool (TPT) and developing Assessment scripts in Python for testing. Tools: MATLAB / Simulink / Stateflow Targetlink Time Partioning Tool (PikeTec) Greenhills Compiler MPC 5516 Micro controller 10

11 Remote Keyless Entry ( RKE) Abstract A Tier-1 Customer who manufactures RKE as an end product for a OEM wanted KPIT To Develop the complete Embedded Software of a Transmitter using a customized chip. This involves complete life cycle of software product development Feature Overview 72 bit Rolling code for encryption of data Hamming byte and Checksum byte for error correction Unique Transmission Identification Code Additional Transmitter Control code generation by multi key presses Low Power RISC 16 bit micro controller Sophisticated Power management using separate IC Tools & Technologies TMS37F136 ASIC which consists of internally MSP430F123 CPU and TMS37134 Transponder, IAR work bench. Metrics 1788 SLOC Effort 217 PD Schedule 9 MM Activities Design and development of RKE application,low level Driver development for push button, SPI, EEPROM State Machine based design approach for features- Multi button press management, button stuck management SPI message for EEPROM access in ASIC RKE protocol transmission in Interrupt with deterministic timing pulse generation. Application development for Interleave, Rolling code generation, checksum and parity calculations Challenges Handled the custom built chip under development with ease which had hardware issues related to Reset, Flashing,Port Interface. Handshaking of ASIC Chip with Micro through SPI Meeting the end needs of OEM on pulse output and debounce timing criteria Memory resource constraints in the Micro controller. 11

12 Sun Roof Control Model Development Overview: Sun Roof Control Module closes sun roof automatically when it receives rain detected information from Rain sensor module. This also closes sun roof if it receives any failure information from MASTER module. Scope : Analyse Requirements Verifying the models against requirements and update the model. Auto code Generation and Optimization. Creating test specification from requirement specification. Testing the model in MIL, SIL and PIL with 100% Code coverage. Analyzing and debugging of the failed test case Challenges: Functional testing using Time Partioning Tool (TPT) and developing Assessment scripts in Python for testing. Tools: MATLAB / Simulink / Stateflow Targetlink Time Partioning Tool (PikeTec) Greenhills Compiler MPC 5516 Micro controller 12

13 Door Lock/Unlock Software Development Overview: Door Lock Control Module This module controls Locking and Unlocking of rear doors This module performs, Emergency opening of the doors during Crash. Trunk Lock Control Module This module controls Locking and Unlocking of the Rear Lid. This module protects the lock unit from getting heated up by executing more locks and unlocks within very short time. Fuel Lock Control Module This module controls Locking and Unlocking of the fuel door. Scope : Analyse Requirements Verifying the models against requirements and update the model. Auto code Generation and Optimization. Creating test specification from requirement specification. Testing the model in MIL, SIL and PIL with 100% Code coverage. Analyzing and debugging of the failed test case Challenges: Functional testing using Time Partioning Tool (TPT) and developing Assessment scripts in Python for testing. Tools: MATLAB / Simulink / Stateflow / Statemate Targetlink Time Partioning Tool (PikeTec) Greenhills Compiler MPC 5516 Micro controller 13

14 Central DOOR LOCK System Context: Body Control module, Lock and Unlock motors directly in accordance with various door lock switch inputs Body control module flash Flasher Output for a confirmation, and send CAN message to Cluster for making click sound and Indicator flashing in Cluster. Scope : Requirement analysis Development of design document based on the requirements. Development of modules in State mate Development of Simulation panel in Statemate Functional Testing Central Door Lock/Unlock Challenges: Matlab experienced engineers learned the Statemate with short span of time and executed the project. Central Door lock Module Speed dependent Door lock Key left protection Auto Relock Configuration for different variant/region Information with out increasing the size of the model. Tools: Statemate / Simulation Panel Shock Detect 14

15 Door Control Unit: Model Based Development & Testing Outline: The goal of this project was to develop and test the software for the DCCU (Door Closure Control Unit) from the design phase to DCCU test phase. DCCU is used in automobiles for closing the half-latched door automatically using a motor Development Platform IAR Systems C' Cross Compiler/Assembler/Debugger MATLAB / Simulink Visio Professional 2000 Emulator and POD Challenges faced The processor literature was insufficient Problem with hardware design wrt sensor interrupt Inputs Received System Requirements Specifications Deliverables Requirements analysis Detailed design document Functional test plan Desk verification report Functional test report Highlights: Details of processor, compiler and linker were researched as the processor was a new one The software design was modified to take care of hardware design fault. 15

16 Lighting Model-Based Design porting Role: Development of model-based design porting Verification of Model Technologies: Matlab; Stateflow; Altia (internal) VC++ (for verification environ) Metrics: Design: 52 transition charts; 58 person-days Verification 1500 test-cases 90 person-days 16

17 Turn Indicator Control- Model-Based Design; Verification Functionality: Indicator feature controls flashing of lights based on the occurrence of events received from the driver or automatic events received from the ECU for flashing. The events may be to flash the lights for certain duration or for continuous flashing, Scope : Requirement Analysis Study and analyse the Target link models Develop test script from Test specification Configure the Model and.mat file in MTEST. Generate automated test reports for MIL and SIL test results using MTEST Automation Tool Analyzing and debugging of the failed test case Flashing of Indicator lights based on exceeding the threshold angle of rotation of the Steering wheel An event to flash the lights when a crash occurs due theft alarm when Warn blinking event is enabled by the driver. Tools: Matlab / Simulink / Stateflow Target link / MTEST Freescale HCS12 17

18 Passive Anti-Theft System (PATS) Abstract -Primary function of Passive Anti-Theft System is to prevent vehicle being driven by unauthorized person. This is achieved by encrypted secret key exchanges between a transponder embedded in key and PCM. -There were some new requirements from OEM to update the software to read and program two new transponders. They needed to auto-configured. Another requirement is to control PATS LED linked to alarm system. Challenges -Updates were required to be done on legacy code that was not having proper documentation. Architecture Diagram Instrument Cluster Diagnostic Connector Theft Indicator CAN Link Starter Motor PCM Transceiver module Fuel injectors Fuel pump Activities Generation of Software Requirement Specification, Design for the entire module as the base work products were not available. Updating the base MATLAB model for the new requirements Updating Code for new requirements as well as MISRA compliance. Unit testing and functional testing of the software Key with transpon der Tools and Technology : -MATLAB/ Simulink, PRQA QA C Tool, Green Hills Compiler for Power PC, Test bench set up with transponder and transceivers Metrics Size: 3508 Lines of Executable code Effort: 8 Person Months 18

19 Immobilizer Software Development Abstract A Tier-1 Semicon Customer who manufactures the Immobilizer chip as an end product for different OEM s, wanted to Develop the complete Embedded Software for the Immobilizer functionality with the different configurations. The OEM s specifications shall be achieved using the configurations. Feature Overview Transponder Operates in Passive Mode (without Battery) and Active mode (with Battery) Secure Key learning process with Encryption Unique Authentication process for security Supports with AES encryption and decryption Supports Manchester and BPLM protocols Base Station Act as a gateway for BCM and Transponder Supports Manchester and BPLM protocols Communicates with BCM either through LIN / SPI Activities Requirement Capturing, Design and development Low level Driver development for Manchester, BPLM protocol with deterministic timing pulse generation Development of LIN and SPI interface with BCM in base station Development for EEPROM access Development for Secure Key Learn process, different Authentication, error handling scenarios Challenges Meeting the end needs of OEM on pulse output timing and power consumption criteria. Memory resource constraints in the Micro controller. Tools & Technologies ASIC which consists of both RKE and Transponder CPU, IAR complier, AVR studio Emulator Setup with Evaluation board (for BS and TP) Metrics Estimated 4035 SLOC Effort Requirement 1.5 mm (completed) Development 22 mm ( to be started) 19

20 HVAC Software Development Powertrain Sensors A/C Request Vehicle Info (ECT & Vehicle Speed) Door Drive & Direction Temperature, Sunload. Door Motors CC RCC Door Position Blower Speed Supply Voltage Ignition Voltage Blower Motor & Controller Power Supply Scope: Porting HC11 to HCS12DP256 Algorithm change Implementation Implementation of state matrix for Integrated Control Panel ICP CAN message Implementation FNOS Integration Boot loader Integration System Validation Diagnostics Tester Faults Commands Displays ICP Externals Functionality: Automatically maintains a selected temperature for vehicle interior. Regulates the volume of air flow inside the vehicle. Automatic selection between FRESH or RE-CIRCULATION air with a manual override. Processes (actions) Data information flows Control information flows Development Platform: IAR Compiler and debugger for Motorola S12DJ64 IAR C-Spy simulator Motorola Flash Gordon unit Challenges: FNOS Integration Porting from D64 (intermediate) to DP256 Unavailability of flashing tool during system testing 20

21 Thank You