Professional Documents
Culture Documents
Electronics
Faculty:
Sankar Dasiga
Why this course?
• KPIT is one of the reasons only!! (Opportunities exist in many Automotive OEMs,
tier 1 / 2 and service companies)
• It is a true domain of application of many courses / topics -
+ Controls
+ Signal Processing
+ Microcontrollers
+ Embedded Systems
+ CCN
+ Programming in C etc
• Use of Electronics in Automobiles is ever increasing so much so, the present day
Automobiles are equally electronic systems as being mechanical systems!!
Electronics is used in the Engine Control (MPFI), Safety (Airbag System), Passenger
Comfort (Controlling the Air-conditioning), Passenger Entertainment (Multimedia
Player), Driver Assistance (Parking Assistance, Navigation, Google Maps) etc
Now there is a push world over on advanced Automotive applications like Collision
Avoidance, Detection of Pedestrian crossing, Vehicle to Vehicle Communication,
Driverless Riding etc
In addition Electronics is used in Diagnostics like – checking of level of Engine, Brake
etc oils / fluids etc
Why this course?
• Automotives are not cars alone .. Nowadays we have lot of
electronics in Two-wheelers, and Buses, and, more has to happen in
vehicles like Goods Transport Vehicles (Tempos, Trucks etc), JCB etc
• Electric vehicles is another area which is fast evolving
Meaning lot more still to come and more opportunities!!!
• It’s a demanding domain with several “Standards” / “Guidelines”
Automotive Standards - for the Hardware
Guidelines such as MISHRA for the Software
As such, if someone has the exposure to and experience of working
with the Automotive Standards / Guidelines, he / she can easily
work on the development of systems for the domains – military,
space, consumer etc
• Several tools are used at various stages of development of
Automotives Electronic Systems; as such knowing about and
understanding them is a significant advantage!!
Besides there are innumerable topic specific white papers and material
Books etc from the vendors / players in the domain available on the net.
Also available on the net are several youtube videos
1. William Ribbens, “Understanding Automotive Electronics”, 6th
Edition, Elsevier
2. Tom Denton: "Advanced Automotive Diagnosis”, 2nd Edition,
Elsevier, 2006
• References
1. Ronald K Jurgen: "Automotive Electronics Handbook, 2nd Edition, McGraw-Hill, 1999
2. James D Halderman: -Automotive electricity and Electronics", PHI Publication
3. Terence Rybak. Mark Stefika: Automotive Electromagnetic Compatibility (EMC), Springer. 2004
4. Allan Bonnick.: “Automotive Computer Controlled Systems” Diagnostic Tools and Techniques". Elsevier Science,
2001
5. Uwe Kieneke and Lars Nielsen: Automotive Control Systems Engine, Driveline and Vehicle, 2nd Edition Springer
Verlag, 2005
6. David Alciatore, Michael Histand: "Introduction to Mechatronics and Measurement Systems (SIE) TMH, 2007
7. Iqbal Husain: "Electric and Hybrid Vehicles: Design fundamentals” CRC Press, 2003.
8. G. Meyer, J. Valldorf and W. Gessner: "Advanced Microsystems for Automotive Applications”, Springer. 2009
9. Tracy Martin: “How to Diagnose and Repair Automotive Electrical Systems" Motor Books/MBl Publishing
Company. 2005.
10. Mehrdad Ebsani. Ali Emadi, Yimin Gao: - “Modern electronic. Hybrid Electric and Fuel Cell Vehicles:
Fundamentals. Theory and Design". 2nd CRC Press. 2009
11. Marc Herniter: “Introduction to Model Based System Design – Rose Hulman Institute of Technology
Trends in Automotive
CAR Technology TRAFFIC DRIVER SKILLS
> 1891 mechanical system very low very high technical skills
> 1920 + pneumatic systems low high technical skills
+ hydraulic systems low driving skills
> 1950 + electric systems increasing good technical skills
increasing driving skills
> 1980 + electronic systems congestion low technical skills
+ optronic systems starts high driving skills
> 2010 + nanoelectronics congested very low technical skills
+ biotronic systems optimization decreasing driving skills
starts
> 2040 + robotics maximal and no technical skills
+ nanotechnology optimized no driving skills
Unit 1
Major Players
Technology
Competition
OEM • Telematics
• Competing on
cost / features • Consolidation • Hybrid fuel
• Collaborative
• Globalized • Overcapacity design
• Distributed operation
• High FG inventory
•Trade union
Customer Market
• Technology • Sluggish growth
adoption differs • Weak economic outlook
• Variety • Globalization
Supply Chain Vs Value Chain
Supply Chain Vs Value Chain
Evolution of Automotive Electronics
• The dawn of automotive electronics came in the early 1970s, when the
only electronics in a car were the radio, the alternator (diodes) and the
voltage regulator that controlled the alternator. The last 30 years have
seen rapid technological innovations in automotive electronics, driven
primarily by advancement in semiconductors and related software that
controls the systems
1. 1970’s: Introduction of electronics for engine controls
2. 1980’s: Anti-lock braking introduced
3. Early 1990’s: Airbags become standard
4. Late 1990’s: Rapid expansion of body electronics – seat motors (body
computers), instrument panel lighting, auto locking systems and keyless
entry
5. Early 2000’s to date: infotainment, including sophisticated audio and
video; signals sent via satellite (such as the OnStar System); GPS and
mapping capabilities; satellite radio
6. Late 2000’s : Steer-by-wire, wireless connectivity
7. Trends 2020 – Connected Cars and Autonomous vehicles
Automotive Electronics Today…
Exchangeability and Reuse – Supply Chain
Evolution of Safety Systems
Some Challenges in Automotive Electronics
Industry
1. Standardization – Hardware as well as Software
2. Availability of hardware components
• Automotive technology cycles exceeding those for semiconductor industry
• Redesign with new components requires extensive validation
www.infineon.com
Electric Power Steering (EPS)
www.infineon.com
Redundancy!!
• Safety critical systems are built with fault tolerance- with
many of its essential information would be derived from
more than one sensor and, handled by more than the bare
necessity hardware (path as well as components)
• For Eg., a brake-by-wire system has three main types
of redundancy:
1. Redundant sensors in safety critical components such as the
brake pedal.
2. Redundant copies of some signals that are of particular safety
importance such as displacement and force measurements of
the brake pedal copied by multiple processors in the pedal
interface unit.
3. Redundant hardware to perform important processing tasks
such as multiple processors for the electronic control
unit (ECU)
• Another example of safety critical system is Steer-by-Wire
brake-by-wire system
Note:
Brake calipers squeeze the
brake pads against the
surface of the brake rotor
to slow or stop the vehicle.
Brake calipersare essential
to your car's ability to stop
and are arguably one of the
most
important automobile brak
e parts. Most carstoday
have disc brakes, at least
for the front wheels
Tools Used in Automotive System Development
• Several tools are used at different stages / phases in the development of
automotive systems – to handle complexities (Several Components /
Features / Versions, Multiple Teams / Functions / Sites, Variants, enforce
standards (automotive standards – for safety etc)
• Some of the examples
– Project Management (Eg., MS Project)
– Supply Chain Management (ERPs such as SAP)
– Requirements Management (Eg., Doors)
– System Modeling (tools for SysML)
– Modeling and Simulation (Eg., MatLab)
– Software Configuration Management (Eg., ClearCase)
– Software Development - IDEs such as Keil with plug-ins for i) enforcing coding
standards such as Mishra, ii) simulation and debugging, iii) emulation of the
hardware
– Test Benches, Test Cases and Tracking of Issues / Bugs (Eg., Jira, Bugzilla)
• Besides innumerable templates and word processing tools are used for
documentation
• Further, several templates are used for reviews (such as documents, code,
test results) are employed
Unit 2
System!!
System Approach
Electronic Systems
Transducer, Sensor and Actuator
• Transducer
A device that converts a signal from one physical
form to a corresponding signal having a different
physical form
– Physical form: mechanical, thermal, magnetic, electric, optical,
chemical...
– Transducers are ENERGY CONVERTERS or MODIFIERS
• Sensor: an input transducer (i.e., a
microphone)
• Actuator: an output transducer (i.e., a
loudspeaker
A System with Sensors and Actuators
Measurement
• The process of comparing an unknown quantity
with a standard of the same quantity (measuring
length) or standards of two or more related
quantities (measuring velocity)
Types of Sensors
• Active vs. Passive
– Does sensor draw energy from the signal ?
• Digital vs. Analog
– Is the signal discrete or continuous?
– Digital sensors
• The signal produced or reflected by the sensor is binary
– Analog sensors
• The signal produced by the sensor is continuous and proportional to the
measurand
• Null and deflection methods
• The signal produces some physical (deflection) effect closely related to the
measured quantity
• Input – Output configuration
– The signal produced by the sensor is counteracted to minimize
the deflection
– That opposing effect necessary to maintain a zero deflection
should be proportional to the signal of the measurand
Calibration
• A sensor or instrument is calibrated by applying a
number of KNOWN physical inputs and recording
the response of the system
Sensor Characteristics
• Static characteristics
The properties of the system after all transient effects have
settled to their final or steady state
– Accuracy
– Discrimination
– Precision
– Errors
– Drift
– Sensitivity
– Linearity
– Hysteresis (backslash)
• Dynamic Characteristics
The properties of the system transient response to an input
– Zero order systems
– First order systems
– Second order systems
Sensor Fundamentals
• Range
– Every sensor is designed to work over a specified range
– The design ranges are usually fixed, and if exceeded, result in
permanent damage to or destruction of a sensor
• Sensitivity
– Sensitivity of a sensor is defined as the change in output of the sensor
per unit change in the parameter being measured
– The factor may be constant over the range of the sensor (linear), or it
may vary (nonlinear).
• Resolution
– Resolution is defined as the smallest change that can be detected by a
sensor
• Response
– The time taken by a sensor to approach its true output when subjected
to a step input is sometimes referred to as its response time.
Sensor Fundamentals
• Linearity
– The most convenient sensor to use is one with a linear transfer function. That is an
output that is directly proportional to input over its entire range, so that the slope of a
graph of output versus input describes a straight line.
• Hysteresis
– Hysteresis refers to the characteristic that a transducer has in being unable to repeat
faithfully, in the opposite direction of operation, the data that have been recorded in
one direction
• Full Scale Output
– Full scale output (FSO) is the algebraic difference between the electrical output signals
measured with maximum input stimulus and the lowest input stimulus applied. This
must include all deviations from the ideal transfer function
• Accuracy
– A very important characteristic of a sensor is accuracy which really means inaccuracy.
Inaccuracy is measured as a ratio of the highest deviation of a value represented by the
sensor to the ideal value. It may be represented in terms of measured value
Accuracy and Errors
• Systematic errors
• Result from a variety of factors
• Interfering or modifying variables (i.e., temperature)
• Drift (i.e., changes in chemical structure or mechanical
stresses)
• The measurement process changes the measurand (i.e.,
loading errors)
• The transmission process changes the signal (i.e.,
attenuation)
• Human observers (i.e., parallax errors)
• Systematic errors can be corrected with
COMPENSATION methods (i.e., feedback, filtering)
Accuracy and Errors
• Random errors
– Also called NOISE: a signal that carries no information
– True random errors (white noise) follow a Gaussian
distribution
– Sources of randomness:
– Repeatability of the measurand itself (i.e., height of a rough
surface)
– Environmental noise (i.e., background noise picked by a
microphone)
– Transmission noise (i.e., 60Hz hum)
– Signal to noise ratio (SNR) should be >>1
– With knowledge of the signal characteristics it may be
possible to interpret a signal with a low SNR (i.e.,
understanding speech in a loud environment
Signal Conditioning
Signal conditioning means manipulating an
analog signal in such a way that it meets the
requirements of the next stage for further
processing
• Attenuation
– Attenuation, the opposite of amplification, is necessary when voltages to be
digitized are beyond the ADC range. This form of signal conditioning
decreases the input signal amplitude so that the conditioned signal is within
ADC range. Attenuation is typically necessary when measuring voltages that
are more than 10 V
• Isolation
– Isolated signal conditioning devices pass the signal from its source to the
measurement device without a physical connection by using transformer,
optical, or capacitive coupling techniques. In addition to breaking ground
loops, isolation blocks high-voltage surges and rejects high common-mode
voltage and thus protects both the operators and expensive measurement
equipment.
Signal Conditioning Techniques
• Filtering
– Filters reject unwanted noise within a certain frequency
range. Oftentimes, low pass filters are used to block out
high-frequency noise in electrical measurements, such as
60 Hz power. Another common use for filtering is to prevent
aliasing from high-frequency signals. This can be done by
using an antialiasing filter to attenuate signals above the
Nyquist frequency.
• Excitation
– Excitation is required for many types of transducers. For
example, strain gauges, accelerometers thermistors, and
resistance temperature detectors (RTDs) require external
voltage or current excitation
Signal Conditioning Techniques
• Linearization
– Linearization is necessary when sensors produce
voltage signals that are not linearly related to the
physical measurement. Linearization is the process of
interpreting the signal from the sensor and can be done
either with signal conditioning or through software.
Thermocouples are the classic example of a sensor that
requires linearization
Automotive Sensors & Actuators
• Automotive manufacturers are continuously
increasing the use of electronics systems to-
– improve vehicle performance
– Safety
– passenger comfort.
• Sensors and actuators integrated with automotive
control computers help optimize vehicle performance
while improving reliability and durability.
SIGNAL
SENSOR
CONDITIONING
A/D CPU
Selection Criteria
• What is to be measured
• Magnitude, range, dynamics of
measured quantity
• Required resolution, accuracy
• Cost
• Environment
• Interface Requirements:
– Output quantity (voltage,
current, resistance,…)
– Sensitivity
– Signal conditioning
– A/D requirements (#bits,
data rate)
Typical Electronic Engine Control System