Simulation Tool Chain for the Estimation of EMC Characteristics of ECU Modules 2007-01-1591

Electromagnetic Compatibility (EMC) requirements and the effort to fulfill them are increasing steadily in automotive applications. This paper demonstrates the usage of virtual prototyping to efficiently investigate the EMC behavior of a gasoline direct injection system.

While the system worked functionally as designed, tests indicated that current and especially future client-specific EMC limits could not be met. The goal of this investigation was to identify and eliminate the cause of EMC emissions using a virtual software prototype including the controller ASIC, boost converter, pi filter, injection valves and wire harness. Applying virtual prototyping techniques it was possible to capture the motor control system in a simulation model which reproduced EMC measurements in the frequency ranges of interest. Using robust design techniques such as sensitivity analysis and deterministic variations of circuit element parameters the critical components in the design were easily identified. With an optimization of the circuitry a reduction of the conducted emissions and power losses could be achieved. Furthermore, we could show the theoretical potential of a redesigned controller ASIC with respect to EMC and power losses.

Consequently, a reduction of costly recursions during the development phase of the system and increased reliability was obtained.