KPIT Cummins

Automotive Body Electronics and Chassis Presentation

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Body and Chassis Practice OverviewPe

ople

1999 2000 2004 2009-10

IndependentVerification & Validation

System Design andFunctional Prototyping

Full Software Development

Maintenance and

Feature Enhancement

Com

pet

ence

150

125

100

75

50

25

10

HIL Testing and

Algorithm Development

• Over 10 years in Body and Chassis

• 125+ projects

• 150+ engineers – Body and Chassis

• 25+ OEMs and Tier 1 Customers

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Body Chassis, Safety and Security Experience

•Keyless and Passive Entry•Immobilizer System•Passive anti theft

•Airbag•Tire pressure Monitor System

•Electric Power Steering•Four wheel drive•Air suspension and Damping•ESC ( Stability Control)• ABS

•Door Control Module, •Power window, •Power Seat , Power mirror• Lift Gate and Luggage Door, • HVAC, Light Control, BCM, wiper control,

Body Chassis

SecuritySafety

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Body and Chassis Feature Development approach

Capability For Majority of feature

Minimal Capability

Complete Capability

Requirement1. User Feature / Idea2. Standardization3. Legislation

Strategy DevelopmentSimulink Model

Strategy Design Validation

Rapid Prototyping

Autocodestatic void mdlTerminate(SimStruct *S) {}

#if defined(MATLAB_MEX_FILE)

ValidationVehicle /HIL

Auto / Manual Coding

Requirement Specification

S R S 3 . 1 . 2S R S 3 . 1 . 2

S R S 3 . 1 . 2

Software Architecture Design

Simulink Model and Verification

(Model in Loop )

Functional Validation(Unit Testing and SIL)

IntegrationOnECU

Calibration Tuning

HIL and Vehicle Validation

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)

Body Case Studies

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Power Seat Module Software Development

AbstractPower 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

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 & TechnologiesStar12D64 Processor, IAR complier Customer specific diagnostic, bootloader tools

Metrics Effort -– 23 man monthsSchedule -15 man monthsResources – 2 to 4 Engineers

Scope• Porting of NOS components• PSM Application enhancement• Development of Application specific Diagnostic Kernel• Validation of PSM on actual seat module

6053 SLOC(Code developed/ modified )

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Power Windows Software Development

System Overviewl Movement of Windows UP and DOWN for Driver,

Passenger and Rear Passengerl Driver Override and Express DOWN (Un Supervisory)l BCM Remote inputsl OFF, CRANK and RUN Power modes supportedl Battery voltage and Current Monitoring through

Analogue inputsl Battery short and Ground short protectionl Up and Down Relay Controll Wheel/steering angle from BCM module (gateway)

Challenges:•Code size in 2Kb, 1624 SLOC• Software in Assembly

Hardwarel 8 bit controller with 8 Mhz in eval boardl Application Flash ROM size of 2Kbl 128 bytes each of RAM and EEPROMl 2 ADCs of 10 bit resolutionl PBA and PBB I/O of 20 portsl WDT at 10 mSec

Softwarel Switch De bounce algorithml Motor Driver Algorithml A2D Algorithml Calibration settingsl Diagnosticsl Scheduler in 10 m Sec loop

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Power Mirror Software Development

AbstractThe scope of the project is to develop the software to control thePower mirror. The driver shall be able to move the driver andpassenger mirror left, Right, Up or Down or even lock using theswitches 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 & Technologies8bit Atmel microMotor control ICAssembly language

Metrics Effort - 149 PDSchedule 5 man monthsResources - 1 to 2 Engineers

SLOC: 1143FLASH: 1572 BYTES (76.8%)RAM: 51 BYTESEEPROM: 18 BYTES

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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

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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)

Front Wiper Actuator This identifies if any blockage is detected in wiping path, reports blockage to master module and comes to parkingposition.

Head Lamp wash This module controls the washing of head lamps

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

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Remote Keyless Entry ( RKE)

AbstractA 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

Challenges• Handled the custom built chip under development with ease

which had hardware issues related to Reset, Flashing,PortInterface.

• 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.

Tools & TechnologiesTMS37F136 ASIC which consists of internally MSP430F123 CPU and TMS37134 Transponder, IAR work bench.

Metrics Effort – 217 PDSchedule – 9 MM1788 SLOC

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

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Scope :Analyse RequirementsVerifying 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 / StateflowTargetlink Time Partioning Tool (PikeTec) Greenhills CompilerMPC 5516 Micro controller

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.

Sun Roof Control Model Development

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Door Lock/Unlock Software Development

Overview:Door Lock Control ModuleThis module controls Locking and Unlocking of rear doorsThis module performs, Emergency opening of the doors during Crash.

Trunk Lock Control ModuleThis 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 ModuleThis 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

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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

Challenges:• Matlab experienced engineers learned the Statemate

with short span of time and executed the project.

• Configuration for different variant/region Information without increasing the size of the model.

Tools:• Statemate / Simulation Panel

Central Door lock Module

Key left protection

Auto Relock

Central Door Lock/Unlock

Speed dependent Door lock

Shock Detect

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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 DCCUtest phase. DCCU is used in automobiles for closing the half-latched door automatically using a motor

Challenges faced• The processor literature was insufficient• Problem with hardware design wrt sensor interrupt

Highlights:Details of processor, compiler and linker were researched as the processor was a new oneThe software design was modified to take care of hardware design fault.

Development Platform• IAR Systems C' Cross Compiler/Assembler/Debugger• MATLAB / Simulink• Visio Professional 2000• Emulator and POD

Inputs ReceivedSystem Requirements Specifications

Deliverables• Requirements analysis • Detailed design document• Functional test plan• Desk verification report• Functional test report

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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

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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,

• 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.

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

Tools:• Matlab / Simulink / Stateflow• Target link / MTEST• Freescale HCS12

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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 toupdate the software to read and program two newtransponders. They needed to auto-configured.Another requirement is to control PATS LED linkedtoalarm system.

Challenges

-Updates were required to be done on legacy code that was not having proper documentation.

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

Architecture Diagram

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

Instrument Cluster PCM

Diagnostic Connector

Theft Indicator

CAN Link

Starter Motor

Transceiver module

Key with transpon

der

Fuel pump

Fuel injectors

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Immobilizer Software Development

AbstractA 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

Challenges• Meeting the end needs of OEM on pulse output timing and power

consumption criteria.• Memory resource constraints in the Micro controller.

Tools & TechnologiesASIC which consists of both RKE and Transponder CPU, IAR complier, AVR studio Emulator Setup with Evaluation board (for BS and TP)

Metrics EffortRequirement – 1.5 mm (completed)Development – 22 mm ( to be started)

Estimated 4035 SLOC

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

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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.

HVAC Software Development

RCC

DoorMotors

Tester ICP

PowerSupply

SensorsBlowerMotor &

Controller

Powertrain

Door Drive& Direction

DoorPosition

BlowerSpeed

SupplyVoltage

IgnitionVoltage

Displays

CommandsFaults

Diagnostics

Vehicle Info(ECT & Vehicle

Speed)

A/C Request

Temperature,Sunload.

Externals

Processes (actions)

Data information flows

Control information flows

Scope:Porting – HC11 to HCS12DP256Algorithm change ImplementationImplementation of state matrix for Integrated Control

Panel – ICPCAN message ImplementationFNOS IntegrationBoot loader IntegrationSystem Validation

Challenges:FNOS Integration Porting from D64 (intermediate) to DP256Unavailability of flashing tool during system testing

Development Platform:IAR Compiler and debugger for Motorola S12DJ64IAR C-Spy simulator Motorola Flash Gordon unit

CC

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Thank You