Professional Documents
Culture Documents
Agenda
Introduction Requirements Definition and Design Constrains Project Life Cycle and Electrical Design Flow Product Definition Design Work Products Component Selection PCB Layout Verification Validation Lab Tour Questions & Answers EMC in Details
Delphi Proprietary www.delphikrakow.pl 2
Evacuation Protocol
Delphi Proprietary
www.delphikrakow.pl
Introduction
This presentation is about: - How we design and test automotive electronic devices
Why it is not easy? Why it is relatively expensive? Why it takes time? and more
Delphi Proprietary
www.delphikrakow.pl
Powertrain
Gasoline EMS Diesel EMS Fuel management and Evaporative Canisters
Steering
Half Shafts Steering Systems
Powertrain
Thermal
Ventilation and Air Conditioning Cooling Systems
Present at TCK
Delphi Proprietary
www.delphikrakow.pl
Requirements Definition
Security
End User
Car
Performance
Functionality
Look
Car Maker
Component
Supplier
System
Electronics
www.delphikrakow.pl
Mechanics
Delphi Proprietary
Software
Tests
6
Design Constrains
Extremal environmental conditions
Thermal schoc: -40/+85.. +125 C Overvoltages ESD Vibrations Humidity Drops (ex. at car production line)
Volume
100k..1000k pcs./year Variants management Price competitive
High reliability
Zero defects at End Of production Line Product lifetime: 10..15years
Safety
Behavior on failures Safe for people and for car
Delphi Proprietary www.delphikrakow.pl
Prototypes
Supplier B
Supplier C
Quote
Validation
Production
Delphi Proprietary
www.delphikrakow.pl
Product Definition
Customer requirements (CDML)
Set of all features and functions for the product Electrical Specification (12/24/42V network, EMC) Environmental (Mechanical, Climatic, Chemical)
Manufacturing requirements
Manufacturing site specific requirements relevant to its technological capabilities
Requirements review
Identify gaps and coherence Check if implementable, testable and manufacturability Example: implement blinkers functionality -> need load specification, timings, what diagnostics is desired
Delphi Proprietary
www.delphikrakow.pl
10
Road vehicles Environmental conditions and testing for electrical and electronic equipment Degrees of protection 2004-06-19 Fire resistance 5 Determination of burning behaviour of interior materials for road vehicles Flammability of materials used in the occupant compartments of motor vehicles Global Automotive Declarable Substance List
www.delphikrakow.pl 11
Delphi Proprietary
Delphi Proprietary
www.delphikrakow.pl
12
Delphi Proprietary
www.delphikrakow.pl
13
Environmental Requirements
Mechanical
Device geometry Vibration loading with superimposed temperature Shock test Drop test Stone chip test Temperature range Stepper temperature test Dewing test Change of temperature test Thermal shock test Dust test Spraying water test Hot water jet test Immersion test Noxious gas test Salt spray test Chemical resitance (fuel, diesel fuel, engine oil, breake fluid, white-spirit, etc.) Burning behavior UV-Light resistance Ozone resistance
Climatic
Chemical
Delphi Proprietary
www.delphikrakow.pl
14
Sharing design tips & hints among engineers before project starts Avoid common problems and pitfalls (especially for inexperienced engineers) Examples
DDS45, Termination of Unused Pins DDS27, Printed Circuit Board Design Standards
Delphi Proprietary
www.delphikrakow.pl
15
Detailed schematics
Delphi Proprietary
www.delphikrakow.pl
16
Floor plan
Guidelines to ECAD for component placement (e.g. group voltage regulators, separate analog vs. digital circuitry) Layer stack allocation (signal layers, ground planes, power supply planes, etc.)
Delphi Proprietary
www.delphikrakow.pl
17
Delphi Proprietary
www.delphikrakow.pl
18
Delphi Proprietary
www.delphikrakow.pl
19
Good Good
68.27 % of the data lies within 1 s of the mean 95.45 % of the data lies within 2 s of the mean 99.73 % of the data lies within 3 s of the mean 99.9937 % of the data lies within 4 s of the mean 99.999943% of the data lies within 5 s of the mean 99.99999980% of the data lies within 6 s of the mean
Bad
Bad
VOP
Root Sum Squares
+ Yields a much more realistic result than WC. + Runs faster than MC + Sensitivity info.
Monte Carlo
+ Yields a much more realistic result than WC. + More accurate than RSS if input distributions are non-normal or component interactions exist
Cons
- There is some risk that in-coming part distributions will be very abnormal resulting in production problems
- There is some risk that in-coming part distributions will be very abnormal resulting in production problems - Most computation required - Because random trials are involved, results not exact.
Delphi Proprietary
www.delphikrakow.pl
20
Time [h]
600 6500 2900 900 700 300 100
Calculation
#
1 2 3 4 5 6
MTBF
Expected device lifetime
Parameter
Yearly mileage Daily mileage Average speed Daily usage Nbr of cranks per day Nbr of "cold' cranks per day
Value
25000km 120km 30km/h 4h 20 4
Delphi Proprietary
Component Selection
AEC-Q100 qualification
Established by Chrysler, Ford, and GM (Automotive Electronics Council) Common part-qualification and quality-system standards for reliable, high quality electronic components Parts compliant with AEC-Q100 for use in the harsh automotive environment
For money...
Review of EBOM to commonize used components Example: origin design: 10 x 10k + 1 x11K, can we use 11x 10k Avoid components obsolescence
Delphi Proprietary
www.delphikrakow.pl
22
PCB Layout
Mechanical dimensions, shape and fixation Heatsink and thermal management Follow EMC/ESD compliance good practices Ensure manufacturability and testability (follow DDS)
Examples: 100% nets with test points Fiducials for optical alignment
Delphi Proprietary
www.delphikrakow.pl
23
Verification
Why?
Avoid design mistakes carry over to next stage
Delphi Proprietary
www.delphikrakow.pl
24
Validation
Design Validation (DV)
Proof model and concept Explore potential design weaknesses
Evaluation criteria
Visual inspection Electrical and physical characteristics measurement Functional checks
Delphi Proprietary
www.delphikrakow.pl
25
Q&A
Delphi Proprietary
www.delphikrakow.pl
26
Immunity
Emissions
ESD
ISO 10605
Emission- discharge of electromagnetic energy Immunity/Susceptibility- level of robustness against the influence of electromagnetic energy
Delphi Proprietary www.delphikrakow.pl 27
I II
A C
Delphi Proprietary
www.delphikrakow.pl
28
DUT
Ground Plane
Closed-Loop Method
RF Amplifier
RF Generator
M od e -S tirre r X M IT A n te n na RCV A n te n na
S im u la to r
1 m h a rne ss
DUT
Delphi Proprietary
www.delphikrakow.pl
29
Switch
DUT
Power Supply Inductive load Load
Delphi Proprietary
www.delphikrakow.pl
30
Harness (Inductive)
Switch
DUT
Power Supply Load
Delphi Proprietary
www.delphikrakow.pl
31
DUT
Power Supply DC Motor
U A
0,9 UA
V
t6
US
Parameters Us Ri td t12 tr t6 12 V system 10 V 0 to 0,05 0,2 s to 2 s 1 ms 0,5 ms 1 ms 0,5 ms 1 ms 0,5 ms
10 %
24 V system 20 V
0V
t tr td
Delphi Proprietary
www.delphikrakow.pl
32
Switch
DUT
Power Supply Inductive load
Delphi Proprietary
www.delphikrakow.pl
33
Switch
DUT
Power Supply Starter Motor
Default values Umin and Ustart are respectively 4.9 V and 6.5 V for the 12 V powernet and 18 V and 21 V for the 42 V powernets
Delphi Proprietary www.delphikrakow.pl 34
DUT
Power Supply Alternator Load
Delphi Proprietary
www.delphikrakow.pl
35
Delphi Proprietary
www.delphikrakow.pl
36
The DUT is connected through the LISN to isolate the batterys ability to filter the transient.
R e la y DUT
I n - lin e f u s e
5 0 o h m t e r m i n a t io n
O p t io n a l C u r r e n t P ro b e
A voltage probe is used to record the transient pulse produced by the DUT when a relay contact is opened.
Delphi Proprietary
www.delphikrakow.pl
37
Delphi Proprietary
www.delphikrakow.pl
38
References
1. 2. 3. 4. 5. 6. 7. International Organization for Standardization official WEB http://www.iso.org/iso/home.htm Wikipedia : http://en.wikipedia.org IEEE Std. 1042-1987 IEEE Guide to Software Configuration Management http://ieeexplore.ieee.org/ Automotive Electronics Council http://www.aecouncil.com/ Automotive EMC http://www.autoemc.net/ Volvo Group Suppliers Portal http://www.volvo.com/suppliers/global/en-gb/supplierapplication/standardsaccess/standards.htm PSA GENERAL TECHNICAL SPECIFICATIONS B217110
Delphi Proprietary
www.delphikrakow.pl
39