1、Automotive E/E Reliability Strategies for Keeping Pace in a Feature-Rich World SAE International technology profiles Automotive E/E Reliability T-126 book 1 11/14/11 9:42 AMOther SAE books of interest: Automotive 2030North America By Bruce Morey (Product Code: T-127) Automotive Electronics Reliabili
2、ty, Volume 2 By Ronald K. Jurgen (Product Code: PT-144) Electronic Control Systems By Ross Bannatyne (Product Code: T-107) For more information or to order a book, contact SAE International at 400 Commonwealth Drive, Warrendale, PA 15096-0001, USA; phone 877-606-7323 (U.S. and Canada only) or 724-77
3、6-4970 (outside U.S. and Canada); fax 724-776-0790; email CustomerServicesae.org; website http:/books.sae.org. T-126 book 2 11/14/11 9:42 AMWarrendale, PA, USA Automotive E/E Reliability Strategies for Keeping Pace in a Feature-Rich World By John Day T-126 book 3 11/14/11 9:42 AM Copyright 2012 SAE
4、International. eISBN: 978-0-7680-7464-2400 Commonwealth Drive Warrendale, PA 15096-0001 USA E-mail: CustomerServicesae.org Phone: 877-606-7323 (inside USA and Canada)724-776-4970 (outside USA) Fax: 724-776-1615 Copyright 2012 SAE International. All rights reserved. No part of this publication may be
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6、-772-4028; fax: 724-772-9765. ISBN 978-0-7680-3499-8 SAE Order Number T-126 DOI 10.4271/T-126 Information contained in this work has been obtained by SAE International from sources believed to be reliable. However, neither SAE International nor its authors guarantee the accuracy or completeness of a
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9、)724-776-4970 (outside USA) Fax: 724-776-1615 Visit the SAE International Bookstore at http:/books.sae.org Library of Congress Cataloging-in-Publication Data Day, John.Automotive E/E reliability : strategies for keeping pace in a feature-rich world / by John Day.p. cm.Includes bibliographical refere
10、nces and index.ISBN 978-0-7680-3499-8 (alk. paper)1. Automobiles-Electric equipment-Reliability. 2. Automobiles-Electronic equipment-Reliability. 3. Motor vehicles-Electric equipment-Reliability. 4. Motor vehicles- Electronic equipment-Reliability. I. Title. II. Title: Automotive electrical/electron
11、ic reliability. TL272.D39 2011629.272-dc23 2011041147 T-126 book 4 11/14/11 9:42 AM Automotive E/E Reliability | Contents | v Contents Preface _ vii Executive Summary _ ix Automotive E/E Drivers _1 Growing Market Demand for Automotive E/E Components and Systems _5 Improving Vehicle Reliability _9 Ch
12、anging “Metal Benders” Mindset _13 Components and Connectors _17 The Automotive E/E Design Chain _27 Defining and Managing Application Requirements _29 Simulation and Verification T ools and T echniques _33 Collaborative Efforts _43 Automotive E/E Industry Standards _47 Looking Ahead _57 References
13、_65 Additional Information _67 About the Author _69 T-126 book 5 11/14/11 9:42 AMT-126 book 6 11/14/11 9:42 AM Automotive E/E Reliability | Preface | vii Preface I imagine that everyone has at least one “stuck on the side of the road” story, and few if any of those stories are pleasant. We want our
14、cars to never break downeverand more than that, we expect them to work perfectly down to the last function, in all kinds of weather, with minimal maintenance. Far more often than not, they do, and that is remarkable considering how complex cars are today, with so many formerly mechanical features an
15、d functions now controlled by electronic circuitry and software. Electrical/electronic (E/E) hardware and software generally makes cars easier, safer, and more fun to drive, but they also have the potential to make cars more failure-prone. This book explores ways that the automotive industry continu
16、es to add E/E features while maintaining if not improving overall reliability. Its a moving target, not easy to reach. E/E reliability is a critical issue for automakers and suppliers as well as for car buyers and dealers. The burden of reliability falls most heavily on automotive E/E engineers, sys
17、tem and software developers, component suppliers, and tool vendors, and in the course of researching this book, I have interviewed individuals representing each of these groups. I am grateful to the engineers, programmers, and senior managers who took the time to walk me through the process of speci
18、fying requirements, designing and verifying applications, applying quality standards, and documenting each step along the way. I gained a clearer idea of how the system works and a deeper respect for the talents and dedication of those who have made it work for the past four decades or more. It was
19、a special pleasure to speak with retired engineering executives Jerry Rivard, Trevor Jones, and Joe Ziomek, among others, from whom I gained perspective on the evolution of auto electronics. Larry Burns helped to put that evolution in context. Executives from General Motors, Ford, Chrysler, and Hyun
20、dai, most quoted by name, were especially helpful, as were systems developers Delphi, Hella, Panasonic, TRW , and Visteon. Electronic design automation (EDA) vendors Mentor Graphics and Synopsys made valuable contributions to my understanding of the design process, as did engineers from firms includ
21、ing dSPACE, National Instruments, and Vector CANtech. Bill Mattingly at ESG Automotive impressed upon me the importance of the V model; Andy Gurd at IBM Rational Systems explained requirements management; engineers from Freescale, Infineon, NXP , Spansion, Renesas, Texas Instruments, and Xilinx outl
22、ined the ways in which semiconductor technology is approaching zero defects; and Paul Geyer and Bill Milam at USCAR gave me a better understanding of connectors and cyber-physical systems, respectively. T-126 book 7 11/14/11 9:42 AMviii | Automotive E/E Reliability | Preface Software developers incl
23、uding LDRA, Reactis Systems, and Vector Software, and CMMI lead appraiser Jeff Dalton at Broadsword Solutions Corporation helped me with the alphabet soup of industry standards. Sin Min Y ap at PTC, Kevin Baughey at Dassault Systmes ENOVIA, and Joe Barkai at IDC put product lifecycle management (PLM
24、) technology in its proper place, and Bruce Lewis and Peter Feiler at the Software Engineering Institute (SEI) filled me in on the reliability potential of architecture description languages. Thanks to Mark Fitzgerald at Strategy Analytics and to other market researchers for the growth estimates the
25、y provided. From Martha Swiss and other members of the SAE International publishing team I learned the difference between writing a book and writing a magazine article or a blog, and from that experience, I contemplated how much easier writing a book would be “next time. ” SAE International provided
26、 introductions to key sources as well as helpful background information from the organizations archives. Finally, gratitude is due to family and friends who expressed confidence in my ability to complete the project and patience when my consistent answer to the “is the book finished?” question was “
27、not yet. ” Now it is, and I hope you will let me know what you think. T-126 book 8 11/14/11 9:42 AM Automotive E/E Reliability | Executive Summary | ix Executive Summary Automakers new car ads increasingly tout vehicles electronic features for connectivity and infotainment, fuel economy, lower emiss
28、ions, performance, and safety. Smartphones and other consumer electronic devices are growing in popularity, and competition compels automakers to accommodate drivers and passengers who expect to use such devices in vehicles and help them do so safely. Electrical/electronic (E/E) technologies that he
29、lp conserve fuel, lower emissions, and/or improve performance and safety include start/stop systems, eco-telematics, adaptive cruise control, and electric power steering. Government mandates in the United States and elsewhere cover tire pressure monitoring and electronic stability control, and camer
30、a systems may soon be added to the list. Growing Market Demand for E/E Components and Systems Those new features are creating demand for E/E components and systems. The research firm Strategy Analytics estimates the world market for automotive E/E systems at $160 billion in 2010 and expects the mark
31、et to grow at a compound annual rate of 9.4% through 2015, exceeding $249 billion. Demand is growing for powertrain systems, electronic controllers, sensors, and connectivity solutions. IMS Research expects the percentage of new vehicles fitted with telematics systems for two-way communication will
32、grow from 9% in 2009 to 46% in 2017. The number of new vehicles with Internet access will grow from 1.1 million in 2009 to 6.0 million in 2017. The market for automotive semiconductor devices totaled $20 billion in 2010, according to Semicast Research Ltd., which predicts that the market will reach
33、$39 billion in 2017. Improving Reliability Automakers generally believe that their vehicles are more reliable these days, even though they are far more complex and technologically sophisticated than ever before. Overall vehicle dependability improved from 2010, according to the J.D. Power and Associ
34、ates 2011 U.S. Vehicle Dependability Study, but automakers are experiencing increased rates of problems with electronic features, such as audio, entertainment, and navigation systems, and new safety features, such as tire- pressure-monitoring systems. Improving the dependability of newer features is
35、 an important point of differentiation among automakers. Systems Engineering Some 40 years ago, when Jerry Rivard began his career in automotive electronics, auto executives were “metal benders” who saw little if any value in E/E technology. Rivard and others set about the task of changing automotiv
36、e executives mindset. T-126 book 9 11/14/11 9:42 AMx | Automotive E/E Reliability | Executive Summary Rivard, Trevor Jones, and other automotive E/E engineering managers introduced systems engineering concepts. Rivard explains, “Y ou cant just look at a car component by component. Y ou start out loo
37、king at total requirements, then, using good computer models, you generate requirements from the major systems to the subsystems and down to the component level. They are doing that today, but it took a long time to get that thinking instilled. ” 1 Finding and Fixing Corner Cases The automotive desi
38、gn chain includes hardware intellectual property (IP) providers, semiconductor vendors, subsystem suppliers, and system integrators, all interacting with suppliers of software IP and tools. Frequently a single function involves multiple electronic control units (ECUs), which may come from different
39、vendors, plus application software, communication software stacks, and operating systems. So much software, communication, and underlying computing complexity creates the potential for countless possible scenarios, most of which represent corner casessituations that only occur outside of normal oper
40、ating parameters. Automakers need a rigorous methodology that recognizes the existence of corner cases, searches for them, and enables engineers to fix them. Figure 1. GM engineers used IBM Rational software and simulation tools to develop electronic controls for the 2011 Chevy Volt battery system,
41、electric drive unit, and cabin electronics. (Courtesy of IBM Rational Systems) T-126 book 10 11/14/11 9:42 AM Automotive E/E Reliability | Executive Summary | xi Managing Design Requirements to a V Automotive E/E application development today begins with a requirements definition, follows the V mode
42、l, and makes extensive use of simulation. “Managing requirements is a continual process that goes throughout the left side of the V , ” says Andy Gurd, market manager for IBM Rational DOORS requirements management software. “Y ou shouldnt test against what you have designed and built. Instead, you g
43、o back and verify that what you built meets the requirements. The value in doing that comes in the form of reduced rework. Testing is more focused, and the overall cost of quality is reduced. ” 2 Simulation and Verification Requirements management software like DOORS verifies that requirements have
44、been met. Simulation deals with how the requirement will be met and how the application relates to other applications. Early simulation allows engineers to identify problems resulting from poorly defined requirements and to test many more scenarios than would be possible from a physical prototype. E
45、lectrical/ electronic systems are becoming more reliable in part because of the increased validation made possible by current technology, including rapid prototyping and hardware-in-the-loop (HIL) testing; however, the complexity of the testing problem is growing faster than the solutions available.
46、 Industry Standards Contribute to Zero Defects Integrated circuit reliability has improved dramatically since Rivards day, when AQL (average quality level) ranged from 1 to 4 per 100. The industry goal became zero defects, which required deep changes in semiconductor industry practices. The Automoti
47、ve Electronics Council (AEC; http:/) was established by Chrysler, Ford, and GM for common-part-qualification and quality-system standards, including AEC-Q100 for semiconductors and AEC-Q200 for passive components. ISO 9000 is a basic quality system. ISO/TS 16949 has additional requirements to produc
48、e the kind of quality and reliability needed by the auto industry. Production part approval process (PPAP) and failure mode and effects analysis (FMEA) are both required elements in ISO/TS 16949 certification. The U.S. Council for Automotive Research (USCAR) developed a standard, SAE/USCAR-2, that gave Ford, GM,
