ECU Measurement Calibration and Diagnostics Brochure
Content
Measurem Measurement, ent, ECU Calibration, and Diagnostics – Development Developme nt Solutions for Automotive Embedded Systems
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Contents
1.
Introduction
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2.
Applications
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3.
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5.
2.1 Calibrating Automotive Electronic Systems 2.2 On- and Offboard Diagnostics
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2.3 Vehicle Testing
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2.4 Process Integration
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2.5 Frontloading
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2.6 Automation
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INCA Product Family
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3.1 Measurement and ECU Calibration
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3.2 Diagnostics
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3.3 Measure Data Analysis
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3.4 Simulation and Prototyping
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3.5 Measurement and Calibration at the the Test Bench
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3.6 Open Interfaces
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Hardware Hardwar e Products
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4.1 Universal ETK/XETK ECU Interfaces
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4.2 ECU and Bus Interface Modules
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4.3 Measurement Modules
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4.4 Unattended Logging of INCA Data
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Application Engineering Services
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1.
Introduction
ETAS provides development tools for measurement, calibration, and diagnostic (MCD) to automakers (OEMs) and suppliers worldwide. ETAS hardware and software products form an integral part of the development process, assisting engineers in everything from developing application software for electronic control units (ECUs) to the integration of automotive electronic systems in the vehicle. This brochure provides an overview of ETAS MCD products and their applications. Engineers use INCA and ETAS ECU and bus interfaces along with measurement modules to calibrate, validate, and diagnose automotive electronic systems and to acquire reliable data from those systems and the vehicle environment. ETAS tools address the requirements of development and testing applications in the laboratory, at the test bench, and on the road. ETAS products and services encompass a wide array of features and benefits: One-stop shopping for full-system solutions with local expert support Comprehensive software tools for advanced applications Compact-sized, rugged hardware designed for automotive environments Scalable and flexible hardware configurations Support of a wide variety of ECU interfaces Acquisition of accurate measurement data Open interfaces compliant with automotive standards ETAS continuously seeks customer feedback and investigates the latest technology trends in order to provide the most innovative products for the development and testing departments of the automotive and commercial vehicle industries. ETAS participates actively in the standardization committees of ASAM, AUTOSAR, FlexRay, JasPar, LIN, Nexus, SAE, and ISO.
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Figure 1: Requirements for measurement, ECU calibration and diagnostic (MCD) tools.
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Figure 2: Chassis applications – driver assistance systems and vehicle dynamics management.
Figure 3: Powertrain applications – conventional and alternative systems.
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2.
Applications
Electrical and electronic systems comprise a substantial segment of the feature and function set of modern automobiles and trucks. The cost efficient implementation of intelligent functions, both within and beyond the domains of powertrain, chassis, and body, is accomplished with the aid of electrics, electronics, and software. As a function of the rising demands on our automobiles’ drivability, convenience, safety, and environmental compatibility, the number and complexity of electronically implemented vehicle functions are increasing steadily. Today’s midsize cars being equipped with engine and transmission controls, electronic brakes, occupant safety, as well as driver assistant and infotainment systems, feature some 40 electronic control units (ECUs). Modern engine control modules process up to 250 MIPS (million instructions per second); these may contain upwards of 20,000 function parameters. The same magnitude applies to the volume of code onboard the ECU, the logical core of all control and diagnostic functions. Modern automotive systems are interconnected by onboard data buses. The engine management is connected to the electronic brake. Adaptive cruise control makes use of position data provided by the navigation system. Hybrid propulsion has to manage engine, transmission, brakes, battery, and electric motor/generator in a combined control approach. New vehicle bus systems such as LIN and FlexRay have been introduced to provide solutions for low cost or high performance requirements. INCA offers connectivity to all relevant bus systems. It provides for calibrating and diagnosing multiple ECUs while monitoring bus communication and acquiring measurement signals from the vehicle environment. INCA supports all standard ECU description formats as well as measurement, calibration, and diagnostic protocols.
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2.1 Calibrating Automotive Electro Electronic nic Systems
ECU software is parameterized in such a manner that the behavior of control and diagnostic functions can be easily adapted to a variety of system variants or vehicle models by calibrating or modifying the characteristic values of function algorithms, without the need to change calculation routines. Using calibration tools, characteristic values can be tuned on-the-fly while at the same time acquiring signals from ECUs, vehicle buses, and measuring devices. Vehicle performance is partially determined by the quality of calibration data. Calibration, i.e., the finding of an optimized set of ECU parameters for a new vehicle, has become a crucial element in the development of new engines and vehicles. It accompanies the development process from the first prototypes until after SOP.
Typical engine calibration tasks for example are: Optimization of base engine paramet parameters ers such as in injecjection, ignition, or valve timing with respect to engine outputs such as power, torque, fuel consumption, and
A main challenge for calibrating complex ECUs are contrary requirements, such as NOx versus CO2 reduction. In addition, calibrations of electronic systems have to be done for a number of different vehicles or model variants which are sold in the different markets. Not only do ten thousands of calibration parameters have to be considered, but also numerous interactions between different software functions and ECUs must be taken into account. Calibration tasks are normally conducted in a work-split between OEM, ECU-suppliers and engineering companies. The tasks are iterated on different levels of detail throughout the development process.
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emission under stationary or transient, and cold or hot temperature conditions. Parameterization of algorithms which derive key engine values such as torque, air and fuel mass, temperatures, or raw emissions by calculations. Optimization of idle-control and driveability to achieve the best trade-off between sportiness and comfort. Parameterization of correlated safety relevant functions such as vehicle dynamics control. Refinement and validation of calibrat calibrations ions under realistic and rough environmental conditions c onditions during test trips.
To manage complex optimization tasks, calibrators require solutions that combine human expertise with best practice optimization methods and easy data handling. INCA offers sophisticated calibration functions and data management capabilities. In addition, INCA provides interfaces to enterprise data backbones for automating calibration procedures. Interfaces enable the integration of INCA functionality into customer specific solutions.
Figure 4: Progress of memory size (in MByte), calibration parameters (number), and calculation power (in mega instructions per second / MIPS) bandwidth of engine control units over the period since 1995.
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2.2 On- and Offboard Diagnostics The need for sophisticated ECU diagnostics onboard the vehicle is mainly driven by legislative standards for onboard monitoring of emission relevant systems such as OBD and EOBD regulations. Offboard in the service shop, correct and efficient identification of faulty components is essential. The ODX Open Diagnostic Data Exchange Format declares onboard diagnostic functions and protocols in a standardized manner. The XML-based data description format enables vehicle manufacturers and their suppliers to maintain all data of the vehicle life cycle, i.e., development, production, and service data, in a uniform way. ODX was specified by ASAM and is published as ISO 22901-1 international standard. More and more car manufactures and suppliers support ODX with their diagnostic development tool chain. Comprehensive vehicle diagnostics requires close cooperation between ECU and service diagnostics development. When offboard diagnostic functions are developed in parallel to the ECU software, they can be tested at an early stage of development. INCA facilitates ECU diagnostics and flash programming compliant to the OBD and ODX standards. Being able to execute software functions and sequences of service testers, INCA provides for the validation of service diagnostics before service tester hardware is available.
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2.3 Vehicle Testi esting ng
Laboratory testing of automotive systems is followed by in-vehicle tests. Road testing shifts from initial trials on dedicated proving grounds to public roadways. Standard drive cycles, e.g., stop-and-go in city traffic, are conducted as well as high-speed runs or tests under various road conditions. In many cases, to verify performance under extreme conditions of temperature and altitude, vehicles are subjected to driving tests in Arctic regions, desert areas or high mountain ranges. Calibration engineers adjust and optimize electronic systems onboard the vehicle with regard to driving characteristics. In addition, thresholds of diagnostic functions are verified against environmental parameters. Vehicle testing has to be very efficient, since development cycles become shorter and the number of test vehicles is becoming more and more limited. Data has to be acquired throughout the entire vehicle trial to maximize test coverage. Drive recorders are an important part of test engineers’ tool sets. For validation tasks performed within the development phase, ETAS offers drive recorders that provide for unattended operation of INCA functions. They replace the laptop with the INCA software and utilize ETAS measurement hardware, ECU and bus interfaces, and INCA experiment configurations. Vast measurement files can be recorded and analyzed by use of the MDA Measure Data Analyzer Analyzer..
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2.4 Process Integration
2.5 Frontloading
Today, the development of complex electronic systems and their attendant ECU software is an effort which is often shared by globally acting workgroups coming from different domains and belonging to different companies. The highly iterative calibration and validation tasks are
Every package of calibration work which can be frontloaded from the vehicle to earlier development phases reduces the need for costly test vehicles, saves valuable engineering resources and helps to locate errors and gaps in the design of vehicle functions at a point in time where
performed in various phases of ECU software, system, and vehicle development. They involve calibration and test engineers as well as function developers, software engineers, diagnostic experts, and documentation teams.
the effort for correction is still low. The use of advanced simulation and prototyping technologies facilitates performing calibration and validation work in the lab, at test benches, or Hardware-in-the-Loop (HiL) systems, or in virtual environments on the PC.
Calibrators require comprehensive information on ECU functions. In addition to displaying control parameter and variable values, a calibration tool must be able to handle graphical representation of software control models, software engineering documentation, calibration history, bus protocol information and much more. INCA provides all the necessary information at one glance.
INCA provides dedicated add-ons for the calibration of ECU function prototypes or simulation models in real or virtual environments. For ECU testing with a HiL system, e.g., in a drive simulation, INCA can be used as a measurement and calibration server.
For integration with customer processes, existing data backbones and tool environments, INCA provides open interfaces and off-the-shelf add-ons to the basic product. It offers standard interfaces to test benches and external applications such as MATLAB®. In addition, INCA comprises a COM-API interface for programming customized applications. Calibration artifacts are often stored in dedicated enterprise data management systems. INCA integrates with all established systems such as Vector eASEE.cdm, AVL CRETA™, or IAV CalGuide. Calibration projects, work results and progress, as well as access rights can be exchanged between INCA and those systems. Calibration and validation tasks are subject to increasing pressure on resources in terms of prototype ECUs, test bench sessions, and test vehicles. To meet cost, time, and quality objectives, development processes constantly demand efficiency improvements. This leads to the general trend of automation and frontloading.
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2.6 Automation
Empirical calibration and validation steps are replaced by predefined procedures which can be fully or partially automated. Automated procedures can be performed in much shorter time: Error prone tasks can be done more dependably and even complex and critical tasks become reproducible. Mathematical optimization algorithms and environment models support effective automation. Automation of calibration and validation tasks may comprise single operations, e.g., ramping up parameter values, or full tests or calibration runs without any human interaction. In the vehicle, calibration procedures which are repeated many times, e.g., when adjusting gear shifts, are often automated. At test benches, automation systems control experiments and perform much of the calibration work. In steady state experiments, measurement and calibration tasks are not performed until the behavior of the unit under test, e.g., the engine, at a certain working point is stationary. Dynamic transient state experiments are more realistic and thus improve the quality of measurement and calibration data. In addition, they minimize automation cycle times. To perform dynamic experiments, rapid measurement and calibration methods are required. The same is true whenever control functions such as knock protection are conducted by the test bench instead of the ECU. In this case, a real time interface between the test bench and the ECU is requested. ETAS’ open and flexible MCD solutions support the automation of measurement and calibration tasks. INCA supports ASAM as well as real time Ethernet protocols, providing remote access for test bench automation systems. In addition, application programming interfaces are provided.
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Figure 5: Forecast: calibration efforts will be shifted from the vehicle to the test bench and to the PC.
Figure 6: INCA provides open interfaces for integration with existing processes, data backbones, and tool environments.
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3.
INCA Product Family
With INCA, ETAS offers a flexible family of software products for calibration, diagnostics, and validation of automotive electronic systems. INCA is successfully employed in more than 20,000 installations worldwide. It comprises all functions required by development, calibration, and test engineers to validate, adapt, and debug ECU application software. INCA is easy to use and offers user-oriented interfaces available in English, German, French, Chinese, or Japanese. INCA is used throughout the development process from the initial calibration of a function model, to the pre-calibration of an ECU at the test bench, to the final optimization in the vehicle. It is deployed at the desk, in the lab, at the test bench, and in the vehicle. Applications range from PC simulations to vehicle instrumentation and from offline management of calibration data to measurement analysis. INCA supports the full line of ETAS compact hardware modules and the powerful ETK/XETK ECU interfaces in measurement, prototyping, calibration, and diagnostic applications. For effortless integration into different environments, INCA offers a wide range of open and standardized interfaces.
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3.1 Measurement and ECU Calibration
3.2 Diagnostics
INCA facilitates the adjustment of function parameters, maps, and tables either offline or during ECU runtime. In the course of this, the tool manages the ECU’s volatile and non-volatile data memory and resolves parameter dependencies. Powerful editors display scalars, curves,
ECU diagnostics is added to the measurement and calibration functions by the ODX-LINK complement to the INCA basic product.
or maps as tables or graphs in physical or hexadecimal format. Calibration scenarios embrace multiple parameter values of specific functions and ease the comparison of different settings.
lated signals in parallel. Both types of signals can be used for triggering and calculation of derived signals in the same manner. All data are recorded in one measurement file and displayed in the same views. A single ECU and bus interface module can provide connections for both, ECU diagnostics and calibration.
For offline management of calibration data, INCA offers sophisticated functions for listing, comparing and merging datasets. In addition, INCA supports processing of meta data describing the history and maturity of a parameter or function calibration. In parallel to calibration, INCA provides for the acquisition of data from the ECU and vehicle busses such as CAN, LIN, Ethernet, and FlexRay. In addition, INCA measures signals from sensors and the vehicle environment. Quantities derived from measurements and calibration variables can be calculated and displayed online. Data recording may be started and stopped by sophisticated trigger conditions. Parallel recording of data related to different trigger conditions is possible. Data records comprise measured and calculated signals, calibration parameters, trigger options, user comments, as well as ECU memory dumps.
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INCA/ODX-LINK acquires calibration and diagnostics re-
ODX-LINK integrates scan tool functions based on diagnostic services required by OBD emission regulations. Being based on the services defined by ISO 15031-5 and SAE J1979 only, the easy to use OBD scan tool visualizes fault memory entries, status information of monitoring functions, vehicle information, in-use monitor performance ratios, and environmental data known as freeze frames. Beyond OBD, ODX-LINK facilitates full diagnostics of ECUs compliant to the ODX standard. In addition, INCA can emulate a service tester and execute troubleshooting functions. In this way, service diagnostics can be validated long before service tester hardware is available. Also including a remote-operable ODX-FLASH tool, INCA/ODXLINK provides a complete solution for validating ODXbased vehicle diagnostics and ECU reprogramming.
Figure 7: With ODX-LINK, INCA provides a complete solution for the validation of vehicle diagnostics and flash programming.
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Figure 8: From electronic control units to experimental systems to virtual environments on the PC, INCA connects to all kind of targets employed for simulation, protoyping, test, and production.
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3.3 Measure Data Analysis
3.4 Simulation and Prototyping
In the ECU development process, measurement data that relate to different variants of calibration parameter values have to be compared. The MDA measure data analyzer is used to visualize, post process, analyze, and document measurements. It provides for evaluating the correlation
The comprehensive measurement and calibration capabilities of INCA can be most beneficially employed in PC simulation and prototyping applications. Simulating the behavior of new software functions in a modeling environment on the PC is an established development
of diagnostic data with signals from the ECU, sensors and vehicle busses. By use of predefined configurations, measurements can be displayed in a uniform manner. By using the same views and settings for the same signals independent of the individual record, similar measurements can be easily checked against each other. MDA print layouts are adaptable to corporate design rules and provide for a professional documentation of the measurement results.
method. Prototypes are used to validate new functions in a real environment.
In the course of simulating, prototyping, or testing functions, measurement data often serve as stimuli. MDA is used to select and prepare stimuli signals from raw measurement data which was recorded at the test bench or in the vehicle. MDA is capable to process large amounts of measurement data. It supports the MDF file format, an ASAM standard which is commonly used by development and test tools.
Function prototypes can be implemented on different targets. As required, they may be executed on an ECU, an experimental system, or a PC. Regardless of the simulation or prototyping environment that is employed, INCA provides add-ons that establish measurement and calibration access. INCA-SCX connects to generic simulation environments on the PC using the XCP protocol over TCP/IP connection. INCA-SIP links INCA with Simulink®. ETAS’ INTECRIO facilitates integration of generic C code, Simulink and ASCET models within one prototype. INCAEIP provides full access to INTECRIO prototypes running on the PC and to INTECRIO or pure ASCET prototypes implemented on an experimental system. By using the same INCA tool at each step, calibration values can be easily refined.
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3.5 Measurement and Calibration at the Test Bench For integration with test bench automation systems, INCA supports the established ASAM interfaces, i.e., the ASAP3 protocol and the ASAM MCD-3 MC object model. The calibration cycle times that can be realized with these standard interfaces are well suited for steady state experiments. Rapid measurement and calibration methods are supported by the INCA-MCE Measurement and Calibration Embedded add-on to INCA. By providing real time connection of the test bench automation tool to the ECU, INCA-MCE provides for outstanding measurement and calibration performance. INCA-MCE runs on the ES910 module serving as real time ECU interface. Either the standard EtherCAT or the application specific iLinkRT Ethernet real time protocol is employed to connect ES910 with the test bench. Using these protocols, the automation tool and INCA-MCE exchange measurement and calibration parameters as physical values addressed by name. To communicate with the ECU, INCA-MCE transforms all data into the appropriate binary values and memory addresses.
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Figure 9: INCA-MCE connects the ECU with test bench automation systems in real time.
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3.6 Open Interfaces
In addition to automation system interfaces, the tools of the INCA product family provide a wide range of open and standardized interfaces for configuration, data exchange, documentation, automation, and integration with customer applications. ECU access is configured by using description files in A2L and ODX format as defined by the ASAM MCD-2 standards. Bus communication on FlexRay, CAN, and LIN is described in the respective FIBEX, CANdb, or LDF format. Calibration data are stored in hex formats, whereas several ASCII formats are supported to exchange subsets of calibration parameters. Measure data is recorded in MDF files. Being a de-facto standard in automotive testing, the binary MDF measurement data format is supported by commonly used data evaluation tools such as MATLAB® and FAMOS.
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INCA provides parameter listings and the results of calibration data in XML-format. The configuration of experiments and connected hardware also can be documented in XML-files. To provide for interactive access of parameter and function model descriptions within INCA, an open interface facilitates integration of electronic ECU documentation in PDF or Windows® Help HTML format by the customer. For tool integration, INCA offers application programming interfaces (APIs). The COM-API is based on the Microsoft COM (Component Object Model) standard. COM-API facilitates remote control of almost all INCA functions and provides maximum flexibility. Using INCA-MIP, INCA-MIP, MATLAB® scripts can be employed to automate or semi-automate calibration procedures. Manual input provided to the scripts by INCA-MIP can be combined with numerical calculation and optimization routines that utilize the rich MATLAB® libraries and toolboxes.
Figure 10: Open interfaces of the INCA product family.
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4.
Hardware Products
Figure 11: ETAS hardware products supported by INCA.
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4.1 Universal ETK/XETK ECU Interfaces
The high standards in terms of performance, safety, responsiveness, drivability, fuel savings and emissions met by today’s vehicles would not be attainable without the deployment of ECUs featuring a multitude of sophisticated functions. Powerful measuring and calibration
In contrast to alternative methods which burden the ECU program with the task of both data access and data transfer through a serial interface, an ETK or XETK calls for very little computing overhead on the part of the ECU. On engine ECUs, for example, large numbers of measured
access constitutes an essential prerequisite for developing these functions and calibrating the function parameters.
values can be acquired easily without impact on ECU overhead, even in the presence of high engine speeds with their substantial burden on computing power.
The Ethernet-based ETK and XETK interfaces by ETAS provide direct access to the control variables and parameters of an ECU via the parallel data and address bus, or via a serial microcontroller testing or debugging interface. The ETK/XETK interface is real-time capable. Its dedicated power supply enables the preparation and initiation of cold-start testing independently of the ECU. Due to their extremely compact design, ETKs/XETKs can be accommodated inside the housings of production ECUs. They are impervious to the temperature extremes and vibrations at the ECU’s location in the vehicle.
Due to their construction, ETK/XETK development ECUs do not require an additional serial interface to connect to the development tool. As a functionally and physically separate addition to the ECU, ETKs/XETKs facilitate direct comparison between the behavior of the development ECU and its production counterpart. Using an ETK/XETK development ECU, series-production software can be calibrated with great ease and subsequently verified with the production ECU without the need to change drivers in the platform software.
ETK-7.1 XETK-T2.1 XETK-V1.0
ETK-S3.0
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Figure 12: Mounting example ETK/XETK-of type VertiCal.
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Figure 13: System with multiple XETK-ECUs and an XETK-ECU with multiple microcontrollers connected to INCA.
Microcontroller Type (Manufacturer/Family)
Interface to to ET ETK/XETK
ETK/XETK Type
Products
Freescale MPC5500
Data and address bus
Parallel ETK
ETK-P20.0, ETK-11.0
Data and address bus (standardized VertiCal interface)
Parall Par allel el ETK/ ETK/XET XETK K ETK-V1 ETK-V1.0, .0, XETK-V XETK-V1.0 1.0
NEXUS interface (JTAG)
Serial ETK
ETK-S3.0
Data an and ad address b bu us
Parallel ET ETK
ETK-P4.0, ET ETK-P5.0, ET ETK-P7.0, ET ETK-P8.1, E ET TK-P9.0
NEXUS interface
Serial ETK
ETK-S2.0
Data and address bus
Parallel ETK/XETK ETK-T1.1, ETK-T2.1, XETK-T2.1
JTAG interface
Serial ETK
ETK-S4.2, ETK-S1.1C
Infineon C166, C167
Data and address bus
Parallel ETK
ETK-7.1
NEC V850
NBD
Serial ETK
ETK-S5.1
Renesas SH
AUD II
Serial ETK
ETK-S6.0
AUD
Serial ETK
ETK-S1.1D
Renesas M32R
JTAG
Serial ETK
ETK-S1.1B
Various third-party microcontrollers
Data and address bus
Parallel ETK
ETK-7.1, ETK-11.0
Freescale MP MPC500 Infineon TriCore
Table 1: Overview of ETK types and interfaces for various microcontrollers and microcontroller families from different manufacturers.
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Supported microcontrolle microcontrollers rs ETAS provides a broad portfolio of ETKs/XETKs for the commonly used microcontrollers for engine and transmission ECUs from Freescale, Infineon, Intel, NEC, Renesas, and STMicroelectronics. ETKs/XETKs are designed according to customer requirements, e.g., with regard to memory sizes and mechanical integration with the ECU. ETK and XETK interfaces provide long-term stability and downward compatibility. All of the above add up to a high degree of protection for capital investments in equipment, tools, and training. ETK and XETK provide Ethernet interfaces to development tools ETK and XETK differ in the way the connection between ECU and host application is set up. ETK-ECUs are connected to the PC by means of an interface module which provides for protocol handling. In contrast, XETKs implement a full functional Ethernet interface on board
This facilitates concurrent access by several PC-based software applications to an XETK-equipped ECU. Several XETK data lines can be connected to a host computer through a network module. This option is of interest in the calibration of systems which are either distributed across several ECUs or implemented by an ECU equipped with several processors. In such cases, the XETK data of the various ECUs can be reconciled by means of a hardware-based time synchronization process. Full compatibility ETK and XETK are fully compatible, both in terms of the interface to the ECU and with regard to the physical dimensions. Both interfaces are equally supported by INCA and the INTECRIO and ASCET development tools. Depending on the use case, XETK and ETK, deliver cost advantages. Deploying an XETK eliminates the expenditure for the PC interface module, whereas the ETK is the more cost-effective ECU interface.
to facilitate direct connection to the PC. XETKs utilize the XCP-on-Ethernet protocol for data transfer. By use of this standard, they can be integrated easily into existing tool environments. The XETK is capable of handling up to four XCP communication channels simultaneously.
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ES510
4.2 ECU and Bus Interface Modules The calibration and test engineer’s ability to measure and calibrate an ECU’s control and diagnostic parameters depends on reliable access to the ECU. ETAS provides compact modules that connect the ETK/XETK ECU interface as well as the K-Line, LIN, CAN and FlexRay serial buses to
ES520
the host PC. When it comes to the acquisition of a large number of signals, the ETK or XETK is the optimum ECU interface. To satisfy more moderate performance requirements, serial calibration protocols like the ASAM-specified CAN Calibration Protocol (CCP) or its successor successor,, the Universal Measurement and Calibration Protocol (XCP) - which is specified for CAN, FlexRay and Ethernet physical layers - are often implemented on the development ECUs. The calibration of production ECUs is done on the CAN or K-Line diagnostic interface via a diagnostic protocol such as KWP2000. Signal monitoring on the vehicle buses LIN, CAN and FlexRay complements both testing and calibration applications.
ES580
All compact ECU and bus interface modules are integrated within INCA. INCA provides simultaneous support for the acquisition of ECU and vehicle bus signals via different modules. Measure data acquired by ES500 or ES900 modules from the ECU, the CAN or FlexRay bus are synchronized by INCA with data from sensors and analog sources. The synchronization enables causal analysis as well as error tracking. Figure 14 (see page 35) shows the combined application of measurement and ECU and bus interface modules by an example.
ES585
ES592
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Hardware Component
ECU and Bus Interfaces
PC Interface
ES510 – Network Module
3x Ethernet / XETK
Ethernet
ES511 – CAN and LIN Network Module
2x CAN, 2x LIN, 3x Ethernet/XETK
Ethernet
ES512 – FlexRay Interface Module
FlexRay (2 channels), 3x Ethernet/XETK
Ethernet
ES520 – FlexRay and CAN Interface Module
FlexRay (2 channels), 2x CAN
Ethernet
ES580 – PCMCIA CAN and LIN Bus Interface
2x CAN or 2x LIN
PCMCIA-Slot
ES581 – USB CAN Bus Interface
1x CAN
USB
ES585 – K-Line Interface Centronics
1x K-Line
Parallel Port
ES590 – Interface Module
1x ETK, 2x CAN, 1x K-Line
Ethernet
ES591 – Interface Module
1x ETK, 2x CAN
Ethernet
ES592 – Inter Interface face Module Module
1x ETK, 2x CAN, 2x LIN, 2x Ether Ethernet/X net/XETK ETK
Ether Ethernet net
ES595 – Interface Module
1x ETK, 1x FlexRay (2 channels), 2x CAN 2x LIN, 1x Ethernet/XETK
Ethernet
ES910 – Prototyping and Interface Module
1x ETK, 1x XETK, 2x CAN, 2x LIN
Ethernet
ES920 – FlexRay Module
1 FlexRay node with 2 channels
ES910
ES921 – CAN Module
2x CAN
ES910
Table 2: Interfaces supported by the compact ES500 and ES900 modules.
ES920
ES921
ES910
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ES910 offers high computation power The compact ES910 module is distinguished by its high computation power. power. ES910 lets you easily validate ECU function prototypes whether designed in MATLAB® / Simulink®, ASCET, or coded in C under real-life conditions in the vehicle. The minimum latency interfaces offer ECU and bus access to the prototyped functions in real time. As an option, the ES910 module can c an be equipped with ES920 or ES921 modules offering a two-channel FlexRay node or two additional CAN interfaces. INCA provides for calibrating the functions running on the ES910 simulation controller. At the test bench, ES910 supports time-critical calibration and validation applications by embedding INCA-MCE. To do this, the ES910 module converts and transfers data in real time between the test bed control c ontrol system and the ECU to facilitate automated calibration with short cycle times.
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Figure 14: Sample setup comprising measurement modules and an ES592/ES595 module acting as interface to ECUs and the vehicle busses.
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ES600
ES610
ES611
Hardware Component
Measurement Channels
ES600 – Network Module
Connects 6 Ethernet modules to one Ethernet link
ES610 – A/D Module
16 x Differential voltage
ES611 – A/D Module wi with Se Sensor Su Supply
8 x Differential v vo oltage in including sensor su supply
ES620 – Thermo Module
16 x Universal thermocouple inputs
ES630/ES635 – Lambda Module
1 x Oxygen sensor input
ES631/ES636 – Lambda Module
2 x Oxygen sensor input
ES650 – Thermo and A/D Module
8 x Universal thermocouple inputs, 8 x Differential voltage
Table 3: ES600 Compact Measurement Modules – measurement channels.
ES620
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ES630/ES631
ES650
4.3 Measureme Measurement nt Modules
ETAS measurement modules are suitable for in-vehicle and test bench applications where engineers employ a multitude of sensors to monitor system and vehicle functions. The modules are used for metering electrical potentials, to acquire voltages, frequencies, or counter/timer signals from active and passive sensors, and to monitor temperatures as well as lambda, air-to-fuel or oxygen content values. ETAS provides two series of measurement modules for calibration and testing applications. The compact ES600 measurement modules are designed for use in the passenger compartment or in the trunk of a vehicle. The very small and extra-rob extra-robust ust ES400 micro measurement modules are designed for installation close to the measurement source. They are well suited for applications in the exterior parts of a vehicle, e.g., under the hood. Combined use is possible for all modules of the two hardware series. All measurement modules are integrated with INCA. In parallel with measurement modules, ETAS ECU and bus interfaces can be connected to the compact ES600 or ES51x network modules. As an alternative to INCA, an ES715 Drive Recorder can be used to log measurement data. ETAS measurement modules supply the user with accurate measure values. Thanks to extremely low temperature coefficients and the electrical isolation of individual measurement channels, measurement readings are largely independent of ambient temperature and ground loops. Network Modules provide for combining measuring devices to form a cluster and synchronizing them featuring microsecond accuracy. Measurement channels behave exactly the same, regardless whether they belong to one module or as part of a device cluster. cluster. Based on Ethernet, measurement clusters are capable to transfer high data volumes to the host application. To optimize each measurement’ss time resolution and data rate, each channel surement’ features an individually adjustable data acquisition rate.
ES600 Measurement Modules The metallic housings of the ES600 module family are rugged, compact and easily handled. In standalone operation, a measurement module is connected directly to the PC and to the power supply with the use of a “Y” splitter cable. Using a built-in power saving feature, the modules of the ES600 family automatically switch to standby mode if no PC is connected. ES600 devices quickly interconnect, simplifying the assembly of a module stack with up to six measurement modules. The measuring channels in one stack are connected and time synchronized by a network module. In addition, the ES600 Network Module supplies power to each of the connected measuring devices, with the modules being powered up sequentially to prevent load surges. The network module continuously displays the activities on the connecting line to the connected devices via LEDs, making it possible to monitor the operation of both the module and the connection itself. In equal measure, ES600 Network Modules provide for combining and synchronizing of up to six device clusters. One single cable carrying power and Ethernet signals connects the PC to the governing network module. Separate clusters can be placed at separate locations, e.g., in the trunk of a vehicle or in the cabin floor area. The star topology tolerates the failure of an ES600 module or cluster and offers easy maintenance of the measuring setup. In a complex setup, the user can cause an identification LED to illuminate in order to spot a specific module.
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ES400 Micro Measurement Modules Sensor signals usually require long cable runs to connect c onnect with measurement modules. In the vehicle, this means routing heavy cable harnesses through the bulkhead into the vehicle‘s interior. interior. This wiring technique not only calls for extensive modifications of the vehicle body – the substantial installation and setup efforts also represent a significant cost factor. With the measurement modules of the ES400 product family,, ETAS provides a solution that overcomes the need family for destroying the vehicle body to run sensor cables. The ES400 modules are designed for installation in the immediate proximity of sensors or signals being measured. ES400 module housings are water and dustproof as per IP67 and impervious to acceleration and impact, such as from flying rocks. All connectors are water and dustproof. The modules feature a working temperature range of between –40 °F and 248 °F (–40 °C and +120 °C).
Established practice with modular test bench concepts is to mount the test candidates on pallet systems, and to set up the required connections with the test bench using predefined interfaces. To save valuable test bench time, test objects – engines, for example – are equipped with the necessary sensors and measuring modules prior to their installation at the test bench. The arrangement of modules in close proximity to the sensors and the fact that the data cable represents the only interface to the test bench host computer allows for an easy check of the measurement setup on the pallet offline. The modules of the ES400 family are ideally suited to test bench deployment thanks to efficient test preparation plus their immunity to ambient conditions in terms of vibrations, oil vapor, exhaust gas, and water, water, which are often present at test benches. ES400 measurement signals can be accessed by ES715 drive recorders. In addition, ES400 modules are fully integrated with the ES910 Rapid Prototyping Module and provide signals to function prototypes in real time.
The modules’ very small form factor facilitates installa-
By use of the standardized XCP-on-Ethernet protocol
tion even in otherwise unsuitable voids and corners of the vehicle’s engine compartment, body, or chassis. This minimizes sensor cable lengths which reduces signal distortion and eliminates long sensor cable harnesses. Only a single data acquisition cable has to enter the vehicle’s interior through a “keyhole”.
and a standalone configuration c onfiguration tool provided by ETAS, ES400 modules can be easily integrated with any thirdparty applications. A C-based library is available for integration into software applications that don‘t provide XCP-on-Ethernet drivers. Currently, Currently, ES400 modules are supported by the applications MM6 from Robert Bosch Chassis Systems Control, DEWESoft from DEWETRON, PROVEtech: VA from MBtech Group, and CANape from Vector. Drivers for LabVIEW® are also available.
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ES410
ES411
ES420
Hardware Component
Measurement Channels
ES410 – A/D Module
8 x Differential voltage
ES411 – A/D Module with Sensor Supply
4 x Differential voltage, including sensor supply
ES420 – Thermo Module
8 x Universal thermocouple inputs
ES430/ES432 – Lambda Module
1 x Oxygen sensor input
ES441 – Counter and Frequency Module with Sensor Supply
4 x Counter, timer, or frequency inputs
Table 4: ES400 Micro Measurement Modules – measurement channels.
ES430
ES432
ES441
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ES715
4.4 Unattended Logging of INCA Data Alternative to an INCA-PC, the ES715 Drive Recorder provides for the logging of data from ETAS ECU and bus interfaces and measurement modules. For standalone operation, the ES715 module contains two onboard CAN channels. Configuration and retrieval of measurement
ES600
data is done via an easy to use web interface. The ES715 Drive Recorder runs INCA experiments, but can also be operated if the user is not familiar with INCA. LEDs on the front panel of the device display the measurement status. The setup of the desired measurement parameters is achieved by the creation of an XML file via an INCA experiment environment. ES715 mass storage can be extended by USB memory devices.
ES592
ES650
ES432
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Figure 15: The ES715 Drive Recorder can be connected via an ES592/ES595 Interface Module to multiple ETAS measurement and calibration modules.
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5.
Application Engineering Services
ETAS premium engineering services are based on many years of experience in automotive electronics development. Our globally networked experts provide a broad range of skills. To support our customers in optimizing processes, methods and tool environments, ETAS Application Engineering Services offer training and consulting as well as development, setup, maintenance, and operation of solutions. Training ETAS conducts training at its local training centers or at the customer site. Courses offered range from standardized product training to customized arrangements and coaching to integration support of new process solutions.
Examples for MCD engineering solutions are: Integration of existing assets ssuch uch as drive recor recorders ders or measurement hardware Setup of cold start measuring sys systems tems Construction o off ECU ssignal ignal stimulator stimulatorss Connection to data backbones Support of sp specific ecific serial protocols such as GMLAN, GMLAN, TP2.0 Creation of dat data a converters for proprietary for formats mats Customization of data visualization and analysis Tools for specific purposes such as programming and validation of diagnostic sequences Implementation of customer-specific flash program program-ming
Consulting
Operations
Our consultants provide our customers with professional advice concerning the efficient use, setup, and migration of tools.
Following installation at the customer site, ETAS application engineers are available to provide expert advice to customer projects, e.g., during tool migration.
Customer specific solutions
High-value customer solutions complete the ETAS portfolio of premium measurement, ECU calibration, and diagnostics products. All ETAS engineers are globally networked, service oriented, and focused on our local customers.
ETAS customizes software and hardware products and integrates them into the customer tool environment. Our engineers can develop complete solutions including products from third parties. Upon request, ETAS can also install solutions on site. Maintenance services ensure the availability of custom solutions and include adaptations to additional requirements.
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Contact addresses
ETAS GmbH Borsigstraße Borsigstraß e 14 70469 Stuttgart, Germany Phone +49 711 711 89661-0 89661-0 Fax +49 711 89661-106 [email protected] ETAS S.A.S. 1, place des Etats-Unis SILIC 307 94588 Rungis Cedex, France Phone +33 1 567000-50 Fax +33 1 567000-51 [email protected] ETAS Ltd. Unit 2A Meteor Business Park Meteor Centre Mansfield Road Derby DE21 4SU United Kingdom Phone +44 1332 1332 253770 253770 Fax +44 1332 253779 [email protected] ETAS Inc. 3021 Miller Road Ann Arbor, MI 48103, USA Phone +1 888 ETAS INC Fax +1 734 997-9449 [email protected]
ETAS K.K. Queen’s Tower C-17F 2-3-5, Minatomira Minatomiraii Nishi-ku Yokohama 220-6217, Japan Phone +81 45 222-0900 222-0900 Fax +81 45 222-0956 [email protected]
Vetronix Corp. 2030 Alameda Padre Serra Santa Barbara, CA 93103 USA Phone +1 805 805 966-2000 966-2000 Fax +1 805 965-3497 [email protected]
ETAS Korea Co., Ltd. 4F, 705 Bldg. 70-5 Yangjae-dong, Seocho-gu Seoul 137-889, Korea Phone +82 2 5747-016 5747-016 Fax +82 2 5747-120 [email protected] ETAS (Shanghai) Co., Ltd. 24F, Bank of China Tower 200 Yincheng Road Central Shanghai 200120, P.R. China Phone +86 21 5037 2220 Fax +86 21 5037 2221 [email protected] ETAS Automotive India Pvt. Ltd. No. 690, Gold Hill Square, 12F Hosur Road, Bommanahalli Bangalore 560 068, India Phone +91 80 4191 2588 Fax +91 80 4191 2586 [email protected]
www.etas.com
ETAS/COM_Sar/03.2010
