Dr. Joseph D’AmbrosioECS Process, Methods, & ToolsGLOBAL RESEARCH &DEVELOPMENT

Systems Engineering of GM’s Global EE / SW Product Line

¶ Introduction¶ Embedded Systems Development at GM¶ Product Line Engineering¶ Additional Topics

Outline

¶ Automotive Industry 25+ years– GM, Delphi– Research, Advance

Development, Product Development

– Model-Based Sys. & SW Development, Safety-Critical Systems, Cyber Security, By-Wire Systems, Vehicle Control Systems, VLSI Design & Tools, Testing

– ISO Technical Expert – ISO 26262 Automotive Functional Safety Standard

¶ PhD University of Michigan – EE Design Methods / Optimization

¶ 50+ publications, 7 patents

About Me – Dr. Joseph D’Ambrosio

Warren, MI SHANGHAI, CHINA

PALO ALTO, CA HERZLIYA, ISRAEL

There Has Never Been A Better Time

To Be An AUTOMOTIVE EMBEDDED

SYSTEM ENGINEER

BIG THINGS ARE COMING…

AND WE HAVE A FRONT ROW SEAT!

CURRENT DNA

Powered Mechanically by Internal

Combustion EngineControlled

Mechanically

Energized by Petroleum

Stand-alone

Powered Electrically by Electric Motors

ControlledElectronically

Energized by Biofuels,

Electricity, and Hydrogen

“Connected”

NEW DNA

Totally Dependence on the Driver

Semi/Full Autonomous

DrivingVehicle Sized for Max Use – People

and Cargo

Vehicle Tailored to Specific Use

CADILLAC DRIVER ASSISTANCE / ACTIVE SAFETY

Package 2 – “Driver Assist Package”

Package 1 plus: Full Speed-Range ACC (Stop w/Go Notifier) Auto Collision Preparation (includes

Collision Imminent Braking) Low-Speed Front/Rear Automatic Braking

(Emergency Braking to Avoid Contact)

Cadillac ATSCadillac XTSCadillac SRX

Package 1 – “Driver Awareness Package”

Lane Departure Warning Forward Collision Alert Side Blind-Zone Alert Rear Cross-Traffic Alert Haptic Safety Alert Seat FeedbackAlso includes: Rear Vision Camera Front & Rear Park Assist

Cadillac ATSCadillac XTSCadillac SRX

Front Camera

Rear Camera

Ultrasonic SensorsShort Range Radars

Safety Alert Seat Short Range Radar

Long/Mid Range Radar

Short Range Radars

Front Camera

Ultrasonic SensorsShort Range Radars

Rear Camera

7 7

+ “Warning”

“Warning”

Improving Safety with V2V/V2X COMMUNICATIONS

AUTONOMOUS DRIVING

Rear Vision System– Object detection– Far IR Capability

Short-Range

SensorsLong-RangeScanningSensor

Forward Vision System– Lane tracking– Object detection– Far IR Capability

Short-Range

SensorsLong-Range

Sensors

EnhancedDigital Map

System

UltrasonicSensors

UltrasonicSensors

Dedicated Short-RangeCommunication + GPS (V2V)

Forward Vision System

EN-V VIDEO

¶ Introduction¶ Embedded Systems Development at GM¶ Product Line Engineering¶ Additional Topics

Outline

OUR CONTRIBUTION…

History of GM Automotive Computing• First Embedded Controllers

• 1977 – First GM production automotive microcontroller• Electronic spark timing

• 1981 – All GM North American vehicles use microcontroller-based engine controls

• 3.9M vehicles total, 22K ECMs per day manufacturing rate• 50,000 lines of assembly code, MC6800 – 8-bit 2 Mhz, • Comparison against PC industry

• Today • 40-70 microcontrollers per vehicle• 400K Lines of C Code for an engine control application• 64Mb flash file system for infotainment application

PC Sales(in 1000s)

LDAA #ACPRESURJSR ADCONSTAA ACPRESBRCLR INPUTS,IACREQ,ACPR050 BRESET DIAGMW3,M66DET,ACPR050BRCLR INPUTS,INOAC,ACPR060

ACPR050 BCLR TBIMW,ACPRESHIJMP IMNRO060

. . .

GM Embedded Software History

20001985 1990 1995 2010

Model-basedDevelopment

DEFINITION MODULE Buffer; VAR nonempty, nonfull:BOOLEAN; PROCEDURE put (x:INTEGER); PROCEDURE get (VAR x:INTEGER);END Buffer.

IMPLEMENTATION MODULE Buffer; CONST N=num_lines; VAR in, out: [0..N-1]; n: [0..N];

PROCEDURE put (x:INTEGER);BEGIN IF n<N THEN buf[n]:=x; . . .

ANSI CModula-GM(Ada-like)

AssemblyLanguage

#include <stdio.h>

struct vehicle{ char make[15]; long miles; float operating_costs;};

void show_vehicle(struct vehicle *);

void main(){ struct vehicle car[] = {“Chevrolet: 100000L, 3456.78, Ford, 11000L, 5000.00}; show_vehicle (car)}

void show_vehicle(struct vehicle *vehicle_ptr){ . . .

file.mat

Variable

Calibration

Calibration

Variable

Variable

13

13Variable

Calibration

Cal_File

2005

Classes of Embedded Systems• Deeply Embedded

• Real Time, Possibly Safety Critical• Examples: Electronic Power Steering, Electronic Brake Controls,

Powertrain, Active safety• Development Tools: Simulink/Stateflow• Future SW Architecture: AUTOSAR

• Moderately Embedded• Loosely Real Time• Example: Body Control, Instrument Panel, Heating/Cooling• Development Tools: e.g., Rhapsody• Future SW Architecture: AUTOSAR

• Lightly Embedded• Non Real Time, but may include data streaming; Security is

important• Example: Infotainment Systems• Future SW Architecture: e.g., QNX/Linux, ANDROID, …

Classes of Embedded Systems• Closed-Loop Control Systems

• Based upon control system theory (e.g., PID control)• Examples: Steering systems, braking systems,

propulsion systems• GM Tools: Simulink/Stateflow

• State-Based Systems• Based upon state transition diagrams• Example: Body control• GM Tools: Rhapsody

Classes of Embedded Systems

• Non Safety Critical – no potential to cause harm

• Detect fault, save diagnostic trouble code, possibly alert driver

• Tools: DFMEA, Requirements-Based Testing, …• Safety Critical – potential to cause harm;

timing properties are important• Fail Safe – detect fault, shut down within required fault

response time, warn driver• Fail Operational – detect fault, continue to operate,

possibly in a degraded mode, warn driver• Tools: Preliminary Hazard Analysis, Safety Concept, DFMEA,

Fault Tree Analysis, Requirements Analysis, … Safety Case

¶ Algorithms: Simulink / Stateflow, Rhapsody¶ Plant modeling: Simulink, Saber, GT Power,

AmeSim, CarSim, …¶ Non Functional System Properties

– Timing / Utilization: SymtaS¶ Electrical: Design Architect, Siemens NX¶ DOORS, Gears, Rhapsody, RTC, Synergy

Model-Based Development Environment

¶ Introduction¶ Embedded Systems Development at GM¶ Product Line Engineering¶ Additional Topics

Outline

20

General Motors Electrical, Controls and Software

¶ GM has one of the most complex systems and software product line engineering challenges in the world– 3000 contributing engineers– 300 hierarchical subsystems– Thousands of variant features– Millions of product instances per year– Tens-of-thousands of unique product

variants– Dramatic increase in variation due to

new propulsion systems and active safety

– Global diversity in legislative regulations– Extreme economic and competitive

pressures– Product line and feature set evolves

annually– 15 concurrent development streams20

Build Times 2004-2008Q1

0

20

40

60

80

100

120

2004-Q1

2004-Q2

2004-Q3

2004-Q4

2005-Q1

2005-Q2

2005-Q3

2005-Q4

2006-Q1

2006-Q2

2006-Q3

2006-Q4

2007-Q1

2007-Q2

2007-Q3

2007-Q4

2008-Q1

Quarters

Min

utes

ECMTCMLinear (ECM)Linear (TCM)

System Design Motivation

21

Cost Quality Speed

Volume

Standardization Understanding

Growing Complexity

Global Footprint

0

20

40

60

80

100

120

140

160

180

200

99 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14

Reuse

Safety and Security

GM Enables massive Reuse through Software Product Lines

¶ A Product Line is a set of systems sharing a common, managed set of features that are developed from a common set of core assets in a prescribed way

¶Why Product Line over Products for GM Embedded Software?

– As much as an 85% reduction in effort for a second (third, fourth, etc.) application

– As much as a 70% reduction in field claims overall

R &D / Advanced

Macro Engineering MethodA System of Systems of Systems

Cloud of Standard Solutions

(The Product Line)

Standardized Set of Deployments Each Deployment

Applied to Multiple Vehicles

Best Fit Selection

Change dialog to expand

product line to fill gaps

23

Vehicle Control System Development

24

ACCLDW

LXCCTD

KLEVRP

EngCycIMC

DFI

ACC-v1ACC-

v1ACC-v1ACC-v1ACC-v1LDW-v1

ACC-v1ACC-

v1LXC-v1

ACC-v1ACC-

v1CTD-v1

ACC-v1ACC-v1KLEC-v1

ACC-v1ACC-

v1VRP-v1

ACC-v1ACC-v1EngC-v1

ACC-v1ACC-v1IMC-v1

ACC-v1ACC-

v1DFI-v1

ACC-v1 LXC-

v3

KLEC-v2

VRP-v2EngC-v1DFI-v5

ACC-v3 LXC-

v3

KLEC-v5

VRP-v1EngC-v1DFI-v3

Chevrolet BuickCTD-v1

Controller

Assembly

Requirements

SW Components

Vehicle

Vehicle

Decreasing level of abstraction

Increasing level of integration

Software Product Line - Single Vehicle View

Subsystems – Chassis Engine, etc.

Subsystems – Chassis Engine, etc.

Controllers 1-n

Assembly

Requirements

SW Component

Vehicles

Software Product Line - Single Component View

Decreasing level of abstraction

Increasing level of integration

Represents all builds in the Product Line

Represents all components in the Product Line

Represent all vehicles supported by the Product Line

Software Product Line - Components X Vehicles

¶ Introduction¶ Embedded Systems Development at GM¶ Product Line Engineering¶ Additional Topics

Outline

Additional Topics• AUTOSAR• Multicore systems• Cyber Physical System

• Virtual Development• Multi Domain Models• System Optimization

• Safety-Critical Systems• SysML, AADL, East ADL, SystemC

Thank You!