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Research Report

Unsettled Aspects of the Digital Thread in Additive Manufacturing

2021-11-15
EPR2021026
Additive manufacturing (AM), also known as “3D printing,” now provides the ability to have an almost fully digital chain from part design through manufacture and service. This “digital thread” can bring great benefits in improving designs, processes, materials, operations, and the ability to predict failure in a way that maximizes safety and minimizes cost and downtime. Unsettled Aspects of the Digital Thread in Additive Manufacturing discusses what the interplay between AM and a digital thread in the mobility industry would look like, the potential benefits and costs, the hurdles that need to be overcome for the combination to be useful, and how an organization can answer these questions to scope and benefit from the combination. Click here to access the full SAE EDGETM Research Report portfolio.
Technical Paper

Designing a Next Generation Trailer Braking System

2021-10-11
2021-01-1268
Passenger vehicles have made astounding technological leaps in recent years. Unfortunately, little of that progress has trickled down to other segments of the transportation industry leaving opportunities for massive gains in safety and performance. In particular, the electric drum brakes on most consumer trailers differ little from those on trailers over 70 years ago. Careful examination of current production passenger vehicle hardware and trailering provided the opportunity to produce a design and test vehicle for a plausible, practical, and performant trailer braking system for the future. This study equips the trailer with high control frequency antilock braking and dynamic torque distribution through use of passenger vehicle grade apply hardware.
Technical Paper

Towards Establishing Continuous-X Pipeline Using Modular Software-in-the-Loop Test Environments

2021-09-22
2021-26-0412
Software-in-the-Loop (SiL) test environments are the ideal virtual platforms for enabling continuous-development, -integration, -testing -delivery or -deployment commonly referred as Continuous-X (CX) of the complex functionalities in the current automotive industry. This trend especially is contributed by several factors such as the industry wide standardization of the model exchange formats, interfaces as well as architecture definitions. The approach of frontloading software testing with SiL test environments is predominantly advocated as well as already adopted by various Automotive OEMs, thereby the demand for innovating applicable methods is increasing. However, prominent usage of the existing monolithic architecture for interaction of various elements in the SiL environment, without regarding the separation between functional and non-functional test scope, is reducing the usability and thus limiting significantly the cost saving potential of CX with SiL.
Technical Paper

Connected Vehicles - A Testing Approach and Methodology

2021-09-22
2021-26-0450
With the introduction of Connected Vehicles, it is possible to extend the limited horizon of vehicles on the road by collective perceptions, where vehicles periodically share their information with other vehicles and servers using cloud. Nevertheless, by the time the connected vehicle spread expands, it is critical to understand the validation techniques which can be used to ensure a flawless transfer of data and connectivity. Connected vehicles are mainly characterized by the smartphone application which is provided to the end customers to access the connectivity features in the vehicle. The end result which is delivered to the customer is through the integrated telematics unit in the vehicle which communicates through a communication layer with the cloud platform. The cloud server in turn interacts with the final application layer of the mobile application given to the customer.
Technical Paper

Improved Run Time Error Analysis Using Formal Methods for Automotive Software - Improvement of Quality, Cost Effectiveness and Efforts to Proactive Defects Check

2021-09-22
2021-26-0459
Quality is what determines success or failure. If products are not error-free, reliable and robust, customers will be put off. Criticism is inevitable. Bosch is focusing on this theme and taking appropriate action to improve the quality of automotive software. Runtime errors most often refer to issues that appear during the execution of a program like buffer overflow issues and pointer access out of bounds. They are important to detect as they may cause critical safety, security or business operation concerns. They can potentially cause the critical systems of high-integrity applications to fail, leading to disastrous results and they have been blamed as the root cause of system failure in high-profile examples in automotive software. This has resulted in identifying run-time error detection as critical field of interest where safety-critical embedded software has to satisfy stringent quality requirements by all contemporary safety standards where no run-time errors must occur.
Technical Paper

Onboard Cybersecurity Diagnostic System for Connected Vehicles

2021-09-21
2021-01-1249
Here, we discuss the On-Board Diagnostic (OBD) regulations for next generation BEV/HEV, its vulnerabilities and cybersecurity threats that come with hacking. We propose three cybersecurity attack detection and defense methods: Cyber-Attack detection algorithm, Time-Based CAN Intrusion Detection Method and, Feistel Cipher Block Method. ...These control methods autonomously diagnose a cybersecurity problem in a vehicle’s onboard system using an OBD interface, such as OBD-II when a fault caused by a cyberattack is detected, All of this is achieved in an internal communication network structure.
Technical Paper

A Controller Area Network Bus Identity Authentication Method Based on Hash Algorithm

2021-07-14
2021-01-5077
With the development of vehicle intelligence and the Internet of Vehicles, how to protect the safety of the vehicle network system has become a focus issue that needs to be solved urgently. The Controller Area Network (CAN) bus is currently a very widely used vehicle-mounted bus, and its security largely determines the degree of vehicle-mounted information security. The CAN bus lacks adequate protection mechanisms and is vulnerable to external attacks such as replay attacks, modifying attacks, and so on. On the basis of the existing work, this paper proposes an authentication method that combines Hash-based Message Authentication Code (HMAC)-SHA256 and Tiny Encryption Algorithm (TEA) algorithms. This method is based on dynamic identity authentication in challenge/response made and combined with the characteristics of the CAN bus itself as it achieves the identity authentication between the gateway and multiple electronic control units (ECUs).
Technical Paper

Safe Operations at Roadway Junctions - Design Principles from Automated Guideway Transit

2021-06-16
2021-01-1004
This paper describes a system-level view of a fully automated transit system comprising a fleet of automated vehicles (AVs) in driverless operation, each with an SAE level 4 Automated Driving System, along with its related safety infrastructure and other system equipment. This AV system-level control is compared to the automatic train control system used in automated guideway transit technology, particularly that of communications-based train control (CBTC). Drawing from the safety principles, analysis methods, and risk assessments of CBTC systems, comparable functional subsystem definitions are proposed for AV fleets in driverless operation. With the prospect of multiple AV fleets operating within a single automated mobility district, the criticality of protecting roadway junctions requires an approach like that of automated fixed-guideway transit systems, in which a guideway switch zone “interlocking” at each junction location deconflicts railway traffic, affirming safe passage.
Technical Paper

Streamlined Process for Cloud Based Diagnostics Using Amazon Web Services

2021-04-06
2021-01-0159
In the age of 5G, the cloud constitutes a massive computational resource. Such capability is greatly underutilized, especially for the purpose of vehicle diagnostics and prognostics. Diagnostics and prognostics run mostly in the limited and cost sensitive electronic module of the vehicle. Utilizing vehicle connectivity, along with the massive capability of the cloud would allow the deployment of smarter algorithms that provide improved vehicle performance and operation management. In this paper, a streamlined process to develop and deploy off-board diagnostics is presented. The process included developing multiphysics digital twins and running the diagnostics off-board. It was demonstrated on a fleet of virtual Hybrid Electric Vehicles (HEV). The Digital Twin replica was created using Simulink® and Simscape®. The microcontroller used to demonstrate the diagnostic is a Raspberry Pi hardware running in real time.
Technical Paper

Leveraging Systems Theoretic Process Analysis (STPA) for Efficient ISO 26262 Compliance

2021-04-06
2021-01-0067
There has been a significant increase - both in the content of electronics and software in vehicles as well as in recalls attributed to these components and systems. The advanced features, including the onset of autonomous vehicles accompanied by millions of lines of code in software have exponentially increased the complexity of vehicle systems and decreased effectiveness of many of the safety analysis techniques being used to identify hazards and safety requirements - for example, FMEA, FTA, ETA, etc.- which were invented decades before the existence of complexities of such magnitude. This paper examines a new hazard identification technique formalized by Nancy G Leveson of Massachusetts Institute of Technology (MIT), USA in her book “Engineering a Safer World” and further elaborated in the STPA Handbook co-authored with John P Thomas in March 2018.
Technical Paper

xEV Propulsion System Control-Overview and Current Trends

2021-04-06
2021-01-0781
Propulsion system control algorithms covering the functional needs of xEV propulsion (‘x’ donates P0-P4 configurations) systems are presented in this paper. The scope and foundation are based on generic well-established HEV controller architectures. However, unlike conventional HEV (series, parallel and power split) powertrains, the next generation of integrated electric propulsion configurations will utilize a single micro controller that supports multiple control functions ranging from the electric machines, inverters, actuators, clutch solenoids, coolant pumps, etc. This presents a unique challenge to architect control algorithms within the AUTOSAR framework while satisfying the complex timing requirements of motor/generator-inverter (MGi) control and increased interface definitions between software components to realize functional integration between the higher level propulsion system and its sub-systems.
Journal Article

Implementation Methodologies for Simulation as a Service (SaaS) to Develop ADAS Applications

2021-04-06
2021-01-0116
Over the years, the complexity of autonomous vehicle development (and concurrently the verification and validation) has grown tremendously in terms of component-, subsystem- and system-level interactions between autonomy and the human users. Simulation-based testing holds significant promise in helping to identify both problematic interactions between component-, subsystem-, and system-levels as well as overcoming delays typically introduced by the default full-scale on-road testing. Software in Loop (SiL) simulation is utilized as an intermediate step towards software deployment for autonomous vehicles (AV) to make them reliable. SiL efforts can help reduce the resources required for successful deployment by helping to validate the software for millions of road miles. A key enabler for accelerating SiL processes is the ability to use Simulation as a Service (SaaS) rather than just isolated instances of software.
Journal Article

Using Delphi and System Dynamics for IoT Cybersecurity: Preliminary Airport Implications

2021-03-02
2021-01-0019
Day by day, airports adopt more IoT devices. However, airports are not exempt from possible failures due to malware’s proliferation that can abuse vulnerabilities. Computer criminals can access, corrupt, and extract information from individuals or companies. This paper explains the development of a propagation model, which started with a Delphi process. We discuss the preliminary implications for airports of the simulation model built from the Delphi recommendations.
Technical Paper

Hypervisor Implementation in Vehicle Networks

2020-04-14
2020-01-1334
The hypervisor offers many benefits to the vehicle architecture, both operationally and with cybersecurity. The proposed mitigant provides the structure to partition the various VMs. This allows for the different functions to be managed within their own distinct VM. ...While the cybersecurity applications are numerous, there are also the operational benefits. The hypervisor is designed to not only manage the VMs, but also to increase the efficiency of these via resource management.
Technical Paper

A Safety and Security Testbed for Assured Autonomy in Vehicles

2020-04-14
2020-01-1291
Connectivity and autonomy in vehicles promise improved efficiency, safety and comfort. The increasing use of embedded systems and the cyber element bring with them many challenges regarding cyberattacks which can seriously compromise driver and passenger safety. Beyond penetration testing, assessment of the security vulnerabilities of a component must be done through the design phase of its life cycle. This paper describes the development of a benchtop testbed which allows for the assurance of safety and security of components with all capabilities from Model-in-loop to Software-in-loop to Hardware-in-loop testing. Environment simulation is obtained using the AV simulator, CARLA which provides realistic scenarios and sensor information such as Radar, Lidar etc. MATLAB runs the vehicle, powertrain and control models of the vehicle allowing for the implementation and testing of customized models and algorithms.
Technical Paper

Dyno-in-the-Loop: An Innovative Hardware-in-the-Loop Development and Testing Platform for Emerging Mobility Technologies

2020-04-14
2020-01-1057
Today’s transportation is quickly transforming with the nascent advent of connectivity, automation, shared-mobility, and electrification. These technologies will not only affect our safety and mobility, but also our energy consumption, and environment. As a result, it is of unprecedented importance to understand the overall system impacts due to the introduction of these emerging technologies and concepts. Existing modeling tools are not able to effectively capture the implications of these technologies, not to mention accurately and reliably evaluating their effectiveness with a reasonable scope. To address these gaps, a dynamometer-in-the-loop (DiL) development and testing approach is proposed which integrates test vehicle(s), chassis dynamometer, and high fidelity traffic simulation tools, in order to achieve a balance between the model accuracy and scalability of environmental analysis for the next generation of transportation systems.
Technical Paper

An Integrated View on Automotive SPICE, Functional Safety and Cyber-Security

2020-04-14
2020-01-0145
This increases the attractiveness of an attack on vehicles and thus introduces new risks for vehicle cybersecurity. Thus, just as safety became a critical part of the development in the late 20th century, the automotive domain must now consider cybersecurity as an integral part of the development of modern vehicles. ...Thus, just as safety became a critical part of the development in the late 20th century, the automotive domain must now consider cybersecurity as an integral part of the development of modern vehicles. Aware of this fact, the automotive industry has, therefore, recently taken multiple efforts in designing and producing safe and secure connected and automated vehicles. ...As the domain geared up for the cybersecurity challenges, they leveraged experiences from many other domains, but must face several unique challenges.
Journal Article

Chip and Board Level Digital Forensics of Cummins Heavy Vehicle Event Data Recorders

2020-04-14
2020-01-1326
Crashes involving Cummins powered heavy vehicles can damage the electronic control module (ECM) containing heavy vehicle event data recorder (HVEDR) records. When ECMs are broken and data cannot be extracted using vehicle diagnostics tools, more invasive and low-level techniques are needed to forensically preserve and decode HVEDR data. A technique for extracting non-volatile memory contents using non-destructive board level techniques through the available in-circuit debugging port is presented. Additional chip level data extraction techniques can also provide access to the HVEDR data. Once the data is obtained and preserved in a forensically sound manner, the binary record is decoded to reveal typical HVDER data like engine speed, vehicle speed, accelerator pedal position, and other status data. The memory contents from the ECM can be written to a surrogate and decoded with traditional maintenance and diagnostic software.
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