L'evoluzione Tecnologica Dell'elettronica Automotive

Automotive Forum 2010
L’evoluzione tecnologica dell’elettronica automotive
Riccardo Groppo
Automotive Electronics Design & Development
Orbassano, 26th May 2010

Contents
Setting the scenario
Drivers and trends in the powertrain technology
Approaching the vehicle electrification
Concurrent challenges
Conclusions
May 2010 Automotive Forum 2010 – National Instruments 2

Contents
Conclusions

The evolution path
Nowadays the auto vehicle, which is the result of an evolutive

process initiated one century ago, is considered a mature
product The first “motor
vehicle” (Cugnot,1769)
The auto vehicle is still considered “the solution” to the

demands for individual mobility over the years
Hence the final product is the result of the accurate The first FIAT’s
assembly of more than 15.000 sophisticated, reliable parts passenger car
(FIAT mod. 4 HP, 1899)
and, on top, it is often available at a very attractive cost
(average 12-30 Euro/kg)
As a matter of fact, the ever more demanding requests in terms The last FIAT’s
of sustainable environment mobility are forcing breakthrough city car
solutions which could give rise to a significant discontinuity (FIAT 500, 2007)
with respect to the past
Due to different mobility needs there will be a further

segmentation of its basic components: urban and extra-
urban
The next FIAT’s
urban vehicle

Individual mobility and urban compatibility
Some key figures:

• the average age of the European car fleet is about 8.2 years
• the total amount of vehicle in use (EU-23) in 2008 was 223 mln.
• the average car density per 1000 inhabitants in Western Europe

in 2009 was 470, while in Italy was 601
Hence, it is the same car density as in Los Angeles city,
which has been conceived keeping in mind a massive use of
the automobile.
The same density, with the current types of automobiles,
becomes suddenly critical once it is applied to the urban
areas in the European cities, which were most designed
during the Mediaeval and Renaissance period, strictly
tailored around the human beings (…and this is the reason
of their beauty)
As a consequence the next
Car density in 2008 ( per 1000 population)
Source: ACEA, Global Insight, 2009
challenge will be the
identification of technical
solutions able to cope both
with the right to individual
mobility and with urban
compatibility.
Light vehicles: worldwide production trends
Regional Production (k Units)
Total Production (k Units)

Source: JD Power 2009

Motor vehicles: the European industry
(33% of worldwide
PC production)
(27% of worldwide
MV production)
New Total motor vehicles 2006 Mn units 18 29% of worldwide MV

registration/ (EU25) production
sales
Total passenger cars 2006 Mn units 15,4 33% of worldwide
(EU25) PC production
Employment Motor vehicle 2004 Mn people 2,3

production (EU27)
Total (indirect) EU27 2006 Mn people c.a. 12,6
Turnover ACEA members 2005 Bn Euro c.a. 560

worldwide
Investment ACEA members 2005 Bn Euro c.a. 40 7% of turnover
worldwide
R&D ACEA members 2005 Bn Euro c.a. 20 4% of turnover

worldwide
Tax revenue ACEA members 2006 Bn Euro 360 3,5% of EU15 GDP
from MV worldwide
Source: ACEA, VDA, AAA, Global Insight, Eurostat 2007

Automotive suppliers: the market share
European suppliers are leading the automotive market, both in terms of market
share and technological contents
8
4 Robert BOSCH
5 29
6 Continental
DENSO
Delphi
HITACHI
Keihin
Magneti Marelli
14
20 Others
14
Source: Strategy Analytics, 2009

Automotive electronics systems: the worldwide demand (*)
Auto Electronic System Market Value (B$)
NOTE (*): including ROW Source: Strategy Analytics, 2009

The whole semiconductors market and the automotive (1/3)
Automotive continues to represent a stable portion of the electronic TAM:

it keeps attractiveness, despite low share in the total semiconductor market.
1 7
9
Automotive
26
Communications
Consumer
Data Processing
Industrial
38
19 Military/Civil
Aeropspace
Source: iSupply 2010

• The whole automotive semiconductors market value amounted to 16,5 B$ (2009) and should exceed 33 B$
(2016) with a growth rate (CAAGR) in the range of 7%
• Europe still represents the biggest market (5,7 B$), due to the highest technological contents of its
vehicles, followed by US (3,3 B$) and Japan (3,1 B$).
• The specificity of the automotive applications is demonstrated by the ASIC share ( >10% )
40.000
35.000
30.000
25.000
20.000
15.000
10.000
5.000
0
2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
Automotive Semiconductors
(Including Audio & Sensors) (B$) 19.317 19.105 16.477 19.516 22.510 25.431 28.395 30.505 32.113 33.483

• Worthy to notice the relevance of the silicon based sensors within the automotive semiconductors
market: it should exceed 3 B$ in 2013 with a growth rate (CAAGR) close to 12%
4.000
3.500
3.000
2.500
2.000
1.500
1.000
500
0
2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
Automotive Semiconductor
2.186 2.210 1.891 2.225 2.548 2.884 3.229 3.456 3.605 3.697
Sensors (B$)

Contents
Conclusions

Drivers of the powertrain technology in the next decade (2010-2020)
Environmental requirements
• Reduction of Diesel particulate and NOx emission down to the gasoline
levels (“fuel neutral emissions”)
• Need for ultra-low emissions for urban vehicles in critical metropolitan
areas
Fuel consumption and CO2 emission reduction under the pressure of both
regulation ( e.g. European CAFE) and market (e.g. fuel cost)
Performance and driveability improvement ( “fun-to-drive”)

• Emphasis on increase of dynamic low-rpm torque rather than high-rpm
power

Powertrain technology trends
Strong commitment to achieve superior fuel economy performances
Short to medium term strategy:

• continue evolutionary improvement of internal combustion engines
• rapid introduction of all modern technologies: downsize/turbo, electronic

valve control, S/S, direct injection , DDCT
• electrification/hybrids to complement advances in conventional

technologies
Long term:
• electrification/hybrids will expand once they become a cost effective offer
to the final customer

Contents
Conclusions

Remembering an old wise hint …
“Young man, that’s the thing: you

have it. Keep at it.
Electric cars must keep near to
power stations. The storage battery
is too heavy. Steam cars don’t do
either for they have to keep a boiler
and a fire. Your car is self contained
– carries its own power plant – no
fire, no boiler, no smoke and no
steam”.
Thomas A. Edison to Henry Ford,

Aug. 1896
Source. U.S. National Park, Service

Vehicle electrification: growth trends
5000
India
4500 China
4000
S. Korea
Europe
Excludes ROW • According to most of the analysts there
3500 Japan
will be a remarkable market
Production (k Units)
NAFTA
3000
2500
penetration of EV, PHEV over the next
2000 decade.
1500
1000
However “significant investments by a
500 variety of players will be necessary to
0
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
ensure barriers to market acceptance
Includes full & mild hybrids, plug-ins and pure EVs are tackled and to realize all-electric
Data from Strategy Analytics’ AES Service. Based on NAFTA, Europe,
Japan, S. Korea, India & China Vehicle Production motoring’s potential”. (Source ACEA 2009)
3000
• Requires a fast change at all levels
2500
• driving habits
2000
• supplier chain
kUnits/year
• battery manufacturing
1500
1000
• infrastructure
500
• car service
0
2008 2009 2010 2011 2012 2013 2014 2015
Baseline Moderate Optimistic • Highly pushed by market demands and
WW Electric Vehicle Market Volumes
Source: Strategy Analytics, 2009 government incentives
The vehicle electrification: a wide range of architectures
Bat. 12V board net

Engine HV Bat. DC/DC DC/DC LV Bat.
Mgn
Motor Transmission
Inverter Power split

Inverter
DC/DC Parallel hybrid Engine Generator
Inverter
Bat. 12V board net

HV Bat. DC/DC LV Bat. Motor Trans.
Mgn
Engine
Bat. 12V board net
HV Bat. 30 kW DC/DC
Mgn
DC/DC LV Bat.
Transmission
Engine
Inver. Inver.
Generator Starter
Mot1 Mot2 T
Rect. Reg. Relay
12V board net
LV Bat. μ-hybrid
Two mode
12V board net

Bat. DC/ LV Bat.
HV Bat.
Mgn DC
Serial - hybrid
Engine
Inv-1 Inv-2
Generator Motor Trans.

Moving towards automotive power electronics
The technological transfer of the power electronics from the already existing
industrial domain into the automotive is troublesome and far from being
acceptable:
• qualification process (automotive grade)
• harsh environment (temperature, vibration)
• life time
• reliability
• level of integration
• cost
Courtesy of Infineon/ST Microelectronics

Contents
Conclusions

Automotive electronics: concurrent challenges
• Increased processing performances and large on-board NVM for embedded uCs
• Real time applications: demanding inner control loop timeschedule
Engine Control 50 ms – 5 ms
Transmission Control 2 ms – 1 ms
Hybrids & KERS 100 us – 50 us
• Sub-micron technology for improved performances and reduced

costs
• Achieving zero defects while improving ruggedness through the

Robustness Validation methodology for harsh environment operation
• Wider acceptance of emerging standards such as AUTOSAR and

ISO26262

NVM Technologies & Powertrain Microcontrollers
2 um 1 um 0.35um 0.25 um 0.13 um 90 nm
1978 1990 1998 2000: 2003 2008

6801, 683xx MPC55x 14MT 34 MT 75 MT
4KT, 8 bit CPU 200KT,CISC CPU 7MT, RISC CPU RISC CPU RISC CPU/DSP Z7 Core
World 1st EMS 32 bit @ 20 MHz 512 KB NVM 1.0MB NVM 2.0MB NVM 4.0MByte NVM
32 bit @ 40 MHz 32 bit @ 56 MHz 32 bit @ 150 MHz 32 bit @ >250 MHz
2MB
Embedded
32bit µC
Flash
with
peripherals
Overall processing performance improvement: 32 x
Courtesy of Freescale Semiconductor

Rationale for Multi Core Processors
Multi core Architecture are a significant trend in automotive:

• for getting more MIPS/Watt and more MIPS/mm2
• for keeping under control EMC issues
• for offloading time-critical tasks from main CPU
• for addressing safety relevant automotive applications (i.e. braking,
suspensions, transmissions, hybrid)
Structured SW development faces a few challenges when using a dual core

processors as a target:
• low complexity tasks are running efficiently today on co-processors
• Autosar provides the mainstream route for the majority of automotive dual core
applications (rel.4.0 defines first specs for the implementation of Multi-Core RT-
OS)
• new tools are required to support the development, reuse of legacy code,
validation and qualification.

Going beyond AEC-Q100
• In recent years car makers have experienced new quality challenges arising
from automotive electronic subsystems (i.e. mechatronic units, smart-
sensors).
• In depth failure analysis has clearly demonstrated that complex active
devices which fulfilled the requirements of AEC-Q100 were not sufficiently
robust in the field.
SWIRL control systems- via crack in RAIL pressure systems- ESD via spot
the EEPROM structure
• Methods to reduce qualification efforts while keeping, and even increasing

the device‟s quality level, are of the highest importance.
May 2010 27
Zero defect: from design to manufacturing flow
 Zero Defect Design & Manufacturing 6,000,000 confirmed fail 5,621,853 10

strategies on all automotive product 5,000,000
cum ships 9
8
developments:
Units Shipped, WW
confirmed failures
7
4,000,000
• continuous improvement in order to add new 6
3,000,000 5
learning to ZD foundation
4
• continue to raise the ZD requirements every 2,000,000
3
year for manufacturing 1,000,000

2
1
• introduce „Safe launch‟ process with the 0 0
customer
M r
M pr
Se g
Se g
Ju y
Ja ec
Ju y
Ja ec
D v
Fe 7
D v
8
Mb
b
n
n
p
Noct
Op
Noct
06
Auul
ar
l
Ju
Ap
a
a
n0
n0
Au
Fe
O
J
A
ar
M
Courtesy of Freescale Semiconductor

Automotive safety standard: ISO 26262
• The International Standard ISO 26262 addresses the whole life cycle1 of safety related
systems which include one or more E/E systems and which are installed in road vehicles of
categories M, N and O (See also ISO 3833:1997 “Road vehicles - Types - Terms and definitions”)
• In particular the ISO 26262 :

• provides an automotive specific risk-based approach for determining risk classes (ASILs)
associated to E/E embedded systems
• uses ASILs for specifying the item's necessary safety requirements for achieving an acceptable
residual risk
• provides requirements for validation and confirmation measures to ensure a sufficient and
acceptable level of safety being achieved.
May 2010 29
Contents
Conclusions

Conclusions (1/2)
• The auto-vehicle will remain “the” solution for the individual mobility needs
over the next years
• Breakthrough in car segmentation will likely occur, thus making the urban
mobility sustainable
• The development of future embedded controls requires to concurrently solve

the challenges of quality, safety, reliability, durability, availability and cost.
• The whole development cycle of the automotive product must be drastically

shortened in order to match the time-to-market requests. Reusability and easy
migration of HW and SW components will be mandatory to achieve those
targets.

Conclusions (2/2)
• A tight interaction among the key

players is needed in order to sustain the
market needs with adequate products,
within the expected time-schedule and
quality levels
• Automotive applications will require

improved performances for the next
generation of control systems
• Electronics is “the key” enabling

technology for the vehicle innovation
over the next decades

100.000
90.000 SEGM. G - H
80.000
SEGM. D - E
70.000
60.000
SEGM. I - L2
50.000
40.000
30.000
Cost [Euro] SEGM. A - B - C - L0
20.000
10.000
Weight [kg]
0
600 800 1000 1200 1400 1600 1800 2000 2200 2400

L'evoluzione Tecnologica Dell'elettronica Automotive

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

L'evoluzione Tecnologica Dell'elettronica Automotive

Încărcat de

Drepturi de autor:

Formate disponibile

Automotive Forum 2010

L’evoluzione tecnologica dell’elettronica automotive

Automotive Electronics Design & Development

Orbassano, 26th May 2010

Setting the scenario

Drivers and trends in the powertrain technology

Approaching the vehicle electrification

May 2010 Automotive Forum 2010 – National Instruments 2

Setting the scenario

Drivers and trends in the powertrain technology

Approaching the vehicle electrification

May 2010 Automotive Forum 2010 – National Instruments 3

Nowadays the auto vehicle, which is the result of an evolutive

The auto vehicle is still considered “the solution” to the

with respect to the past

Due to different mobility needs there will be a further

May 2010 Automotive Forum 2010 – National Instruments 4

Some key figures:

• the average car density per 1000 inhabitants in Western Europe

Regional Production (k Units)

Total Production (k Units)

May 2010 Automotive Forum 2010 – National Instruments 6

New Total motor vehicles 2006 Mn units 18 29% of worldwide MV

Employment Motor vehicle 2004 Mn people 2,3

Turnover ACEA members 2005 Bn Euro c.a. 560

R&D ACEA members 2005 Bn Euro c.a. 20 4% of turnover

Source: ACEA, VDA, AAA, Global Insight, Eurostat 2007

May 2010 Automotive Forum 2010 – National Instruments 7

Source: Strategy Analytics, 2009

May 2010 Automotive Forum 2010 – National Instruments 8

Auto Electronic System Market Value (B$)

NOTE (*): including ROW Source: Strategy Analytics, 2009

May 2010 Automotive Forum 2010 – National Instruments 9

Automotive continues to represent a stable portion of the electronic TAM:

Source: iSupply 2010

May 2010 Automotive Forum 2010 – National Instruments 10

May 2010 Automotive Forum 2010 – National Instruments 11

May 2010 Automotive Forum 2010 – National Instruments 12

Setting the scenario

Drivers and trends in the powertrain technology

Approaching the vehicle electrification

May 2010 Automotive Forum 2010 – National Instruments 13

Performance and driveability improvement ( “fun-to-drive”)

May 2010 Automotive Forum 2010 – National Instruments 14

Strong commitment to achieve superior fuel economy performances

Short to medium term strategy:

• rapid introduction of all modern technologies: downsize/turbo, electronic

• electrification/hybrids to complement advances in conventional

May 2010 Automotive Forum 2010 – National Instruments 15

Setting the scenario

Drivers and trends in the powertrain technology

Approaching the vehicle electrification

May 2010 Automotive Forum 2010 – National Instruments 16

“Young man, that’s the thing: you

Thomas A. Edison to Henry Ford,

May 2010 Automotive Forum 2010 – National Instruments 17

Bat. 12V board net

Inverter Power split

Bat. 12V board net

12V board net

12V board net

Generator Motor Trans.

May 2010 Automotive Forum 2010 – National Instruments 19