In Critical Embedded Systems Electronics is central. This presentation focuses on how Automotive Electronics is developped to reach the stringent objectives of this critical systems domain.

1. CISEC January 28th 2014
Electronics development and assurance
Automotive Electronics
Jean-Pierre Loncle
www.continental-corporation.com
Interior Division

2. Continental Corporation
Overview 2012
Sales by division in %
ContiTech
11%
Chassis &
Safety
21%
› Since 1871 with headquarters in Hanover, Germany
› Sales of €32.7 billion
› 169,639 employees worldwide
› 291 locations in 46 countries
› One of the top 3 in the automotive supplier industry
Tires
29%
Powertrain
19%
Interior
20%
Status: December 31, 2012
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3. Continental Corporation
Five Strong Divisions
Chassis & Safety
Powertrain
Interior
Tires
ContiTech
Vehicle Dynamics
Engine Systems
Instrumentation &
Driver HMI
PLT,
Original Equipment
Air Spring Systems
Hydraulic
Brake Systems
Transmission
Infotainment &
Connectivity
PLT, Repl. Business,
EMEA
Benecke-Kaliko
Group
Passive Safety &
Sensorics
Hybrid Electric
Vehicle
Body & Security
PLT, Repl. Business,
The Americas
Compounding
Technology
Advanced Driver
Assistance Systems
(ADAS)
Sensors &
Actuators
Commercial Vehicles
& Aftermarket
PLT, Repl. Business,
Asia Pacific
Conveyor Belt
Group
Commercial
Vehicle Tires
Elastomer Coatings
Fuel Supply
Two Wheel Tires
Fluid Technology
Power Transmission
Group
Vibration Control
PLT – Passenger and Light Truck Tires
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4. Business Unit Body & Security
Product Overview (main products only)
Pneumatic Seat System
Seat Control Unit
Intelligent Antenna Module
Immobilizer
Start-Stop
Button
Central Gateway
Car Key/ID
LED/Lighting and
AFS Control Unit
Central Body
Control Module
Window/Door
and Sunroof
Control Unit
TPMS Sensor (valve mounted)
RKE &
PASE
Control Module
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eTIS Sensor (tire mounted)
DC/DC Converter
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5. Automotive product development
Automotive product constraints
› Custom parts: most of the products are custom to fit OEMS specific requirements and EE architecture
› High volume: Some parts are exceeding 1Mio Unit / year
› Flexibility: Stick to customer needs
› Logistics for purchased parts
› Logistics for finished parts
› Manufacturing volumes, real time adaptation (JIT policy)
› Lifetime: standard is 15 years or 220 000 km
› Management of part change notification, part termination notice
› Quality target: Single digit ppm (part per million) for 0 km failure
› Short response time for failure analysis: 30 days associated to a 8D documentation to identify root
cause, corrective actions and prevent reoccurence
› Automotive Environment requirements: Watertighness, Immunity to disturbances, Low EMC radiation
level, Resistance to fluids, Low current consumption for Permanent Battery supplied parts (<1 mA)…
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6. Automotive product development
Project Cycle and Quality gates
›
G40 Target: Starts the detailed development
›
G50 Target: Product design is completed
›
G55 Target: Starts ordering of components and sourcing of production equipment
›
G60 Target: Starts set up of production line
›
G70 Target: Ready for PPAP
›
G80 Target: Starts series production
›
G90 Target: Series production running
›
Each Gate has to be released prior to enter in next project phase.
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7. Automotive product quality development
How to achieve Quality targets (pre development phase)
›
Upfront validation of new components, technologies and processes prior to Mass
Production
›
›
Motto: Never develop a novelty with the scope of an application project.
Leading to:
›
›
Base development for new technical solutions (eg: new custom component)
Design Of Experiment (DOE) for Technology and process
›
Eg: DOE for pressfit technology
›
Eg: DOE for leadfree solder paste selection to cope with RoHS regulation
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8. Automotive product quality development
How to achieve Quality targets
› To secure component quality and performances by achieving Automotive Electronics Council
(AEC) Q100 (for Active components) Q200 (for Passive components) requirements.
› By adding application oriented specific requirements:
Or Specific Supplier Quality agreements
› By continuously monitoring supplier / technology / component quality performances
› Supplier Audit and 3 level of approvals: Supplier Approval, Component Approval, Manufacturing
Approval
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9. Automotive product quality development
How to achieve Quality targets (Development and PV Phases)
›
›
To successfully product DV (Design Validation) and PV (Product / Production Validation) on
top of design verification
Representative DV/PV tests (Environmental):
Solid Tightness
Liquid tightness Water test
Salt spray
Corrosive atmosphere
Thermal shocks endurance test
Thermal shocks pre-ageing test
Warm storage
Cold storage
Climatic sequence
Temperature range (steps) test
Temperature range (steps) test
Cold operation
Cold and low pressure storage
Withstand voltage test
Insulation resistance test
Check of saturation temperature
Thermal cycling life test
Constant humid heat life test
Thermal life & combined road actuation
endurance
Free fall test
Collision impact test
Endurance to driving shocks test
Falling tool shock test
Curbstone shocks test
Brackets and fasteners resistance test
Terminal strength test
Resonance-point detecting point
Resonance-point oscillation test
Random vibration endurance test
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Standard reference
IEC 60529
ISO/DIS 16750-4
IEC 60068-2-52 Kb
IEC 60068-2-60 Ke
IEC 60068-2-14 Na
IEC 60068-2-14 Na
IEC 60068-2-2 B
IEC 60068-2-1 A
IEC60068-2-38 Z/AD
ISO/DIS 16750-4
ISO/DIS 16750-4
IEC 60068-2-1 A
IEC 60068-2-40 Z/AM
ISO/DIS 16750-2
ISO/DIS 16750-2
Specific
Specific
Specific
Specific
IEC 60068-2-32 Ed: Free-fall
IEC 60068-2-27 Ea : Shock
IEC 60068-2-27 Ea : Shock
Specific
IEC 60068-2-29 Eb: Bump
Specific
Specific
Specific
IEC 60068-2-6 Fc
IEC 60068-2-64 Fh
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10. Automotive product quality development
How to achieve Quality targets (Development and PV phases)
›
Representative DV/PV tests (Electrical & EMC):
Resistance to pulse 1 bis
Resistance to pulse 2a
Resistance to pulse 3a
Resistance to pulse 3b
Resistance to pulse 5a or 5b
Resistance to power supply micro-interruptions
Resistance to starting profile
Resistance to on-board power system voltage ripples
Immunity to signal line transients
Immunity to bulk current injection (BCI)
Immunity to bulk current injection (BCI)
Resistance of inductive load connected circuits
Resistance to impulsive transient
Immunity to radiated field
Immunity to audio frequency magnetic field
Resistance to electrostatic discharges, equipment not
supplied
Resistance to electrostatic discharges, equipment
supplied
Resistance to handy transmitters
Standard reference
ISO 7637-2
ISO 7637-2
ISO 7637-2
ISO 7637-2
ISO 7637-2
ISO16750-2
ISO16750-2
ISO16750-2
ISO 7637-3
ISO 11452-4
ISO 11452-4
Specific
Specific
ISO 11452-2
ISO 11452-8
IEC 61000-4-2
ISO 10605
ISO11452-9
Measurement of conducted transient emission
ISO 7637-2
Measurement of audio frequency conducted emission
Specific
Measurement of radio frequency conducted emission
CISPR 25
Measurement of radio frequency radiated emission
CISPR 25
Measurement of magnetic field radiated emissions
MIL-STD 461 E
ISO16750-2
Resistance to power supply voltages
Resistance to slow decrease and increase power of
suply voltages
Re-initialization test
Resistance to non usual power supply voltages
Resistance to ground and positive supply voltages
short circuit
Safety switch compatibility
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ISO 16750-2.
ISO16750-2
ISO16750-2
ISO16750-2
Specific
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11. Automotive product quality development
How to achieve Quality targets (manufacturing phase)
›
Capability (Cpk) analysis
›
Test results drift analysis
›
Process step FPY analysis and improvement
›
Non conform parts analysis
›
Safe Launch plan
›
Products and component traceability
›
PPAP submission and customer audit
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12. Automotive product quality development
Supporting Tools
›
Design FMEA (Failure Mode Effect Analysis)
›
Process FMEA
›
Worst case analysises
›
FMEDA (Failure Mode Effects and Diagnosis Analysis), FTA (Fault Tree Analysis) for
Safety relevant functions according ISO 26262
›
Design Review
›
Change Management
›
Lessons Learnt
›
R&R (Repetability and reproductibility) Analysis
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13. Thank you
for your attention!
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