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The BMW Group has introduced electric cars to the market with the MINI E already in 2009. The next step will be the launch of the BMW ActiveE in 2011, followed by the revolutionary Mega City Vehicle in 2013. The presentation will explain the BMW Group strategy for implementing sustainable mobility. A focus will be emobility, the use of carbon fiber and the holistic sustainability approach of BMW Group?s project i. Reference will be made to the research results of the MINI E projects in the US and in Europe. Presenter Andreas Klugescheid, BMW AG

A variety of methodologies to use embedded multicore controllers efficiently has been discussed in the last years. Several assumptions are usually made in the automotive domain, such as static assignment of tasks to the cores. This paper shows an approach for efficient task allocation depending on different system modes. An engine management system (EMS) is used as application example, and the performance improvement compared to static allocation is assessed. The paper is structured as follows: First the control algorithms for the EMS will be classified according to operating modes. The classified algorithms will be allocated to the cores, depending on the operating mode. We identify mode transition points, allowing a reliable switch without neglecting timing requirements. As a next step, it will be shown that a load distribution by mode-dependent task allocation would be better balanced than a static task allocation.

To meet LEV and EU Stage III emission requirements, it is necessary for new catalytic converters to be designed which exceed light-off temperature as quickly as possible. The technical solutions are secondary air injection, active heating systems such as the electrically heated catalytic converter, and the close coupled catalytic converter. Engine control functions are extensively used to heat the converter and will to play a significant role in the future. The concept of relocating the converter to a position close to the engine in an existing vehicle involves new conflicts. Examples include the space requirements, the thermal resistance of the catalytic coating and high temperature loads in the engine compartment.

Innovative electric systems demand a new approach for the distribution of electric energy in passenger cars. This paper describes a very promising solution-the dual voltage power network with an upper voltage level of 42V, and the considerations which led to the selection of this voltage level. Owing to the significant impact on the industry, a common standard is required. Depending on their profile, OEMs will select their own strategies for implementation, either as a base for innovation or to enhance overall system efficiency. This will lead to different approaches and timeframes.

Although hydrogen ICE engines have existed in one sort or another for many years, the testing of fuel consumption by way of exhaust emissions is not yet a proven method. The current consumption method for gasoline- and diesel-fueled vehicles is called the Carbon-Balance method, and it works by testing the vehicle exhaust for all carbon-containing components. Through conservation of mass, the carbon that comes out as exhaust must have gone in as fuel. Just like the Carbon-Balance method for gas and diesel engines, the new Hydrogen-Balance equation works on the principle that what goes into the engine must come out as exhaust components. This allows for fuel consumption measurements without direct contact with the fuel. This means increased accuracy and simplicity. This new method requires some modifications to the testing procedures and CVS (Constant Volume Sampling) system.

The study of oil emission is of essential interest for the engine development of modern cars, as well as for the understanding of hydrocarbon emissions especially during cold start conditions. A laser mass spectrometer has been used to measure single aromatic hydrocarbons in unconditioned exhaust gas of a H2-fueled engine at stationary and transient motor operation. These compounds represent unburned oil constituents. The measurements were accompanied by FID and GC-FID measurements of hydrocarbons which represent the burned oil constituents. The total oil consumption has been determined by measuring the oil sampled by freezing and weighing. It has been concluded that only 10 % of the oil consumption via exhaust gas has burned in the cylinders. A correlation of the emission of single oil-based components at ppb level detected with the laser mass spectrometer to the total motor oil emission has been found.

Driven by factors like consumption, power output per liter, comfort and more stringent exhaust gas standards the powertain control area, has developed rapidly in the last decades. This trend has also brought with it many innovations in the ignition application. Today we can see a trend to Pencil-coil or Plug-top-coil ignition systems. The next step in system partitioning is to remove the power driver from the ECU and place it directly in/on the coil body. The advantages of the new partitioning - e.g. no high voltage wires, reduced power dissipation on the ECU - are paid with different, mainly tougher requirements for the electronic components. By using specialized technologies for the different functions - IGBT for switching the power, SPT for protection, supply and diagnostics - in chip-on-chip technology all required functions for a decentralized ignition system can be realized in a TO220/ TO263 package.

As the demand for enhanced comfort, safety and differentiation with new features continues to grow and as electronics and software enable most of these, the number of electronic units or components within automobiles will continue to increase. This will increase the overall system complexity, specifically with respect to the number of controller actuators such as e-motors. However, hard constraints on cost and on physical boundaries such as maximum power dissipation per unit and pin-count per unit/connector require new solutions to alternative system partitioning. Vehicle manufacturers, as well as system and semiconductor suppliers are striving for increased scalability and modularity to allow for most cost optimal high volume configurations while featuring platform reuse and feature differentiation. This paper presents new semiconductor based approaches with respect to technologies, technology mapping and assembly technologies.

Increasing fuel costs and emission regulations force the car manufacturers to develop powerful but efficient engines. The 3-liter car (3-liter/100 km fuel consumption → 80 miles/gallon) is one of the slogans. To fulfill these requirements a fully electronic controlled Engine Management is necessary. Carburetor systems are replaced by fuel injection systems. Direct injection for Diesel as well as for gasoline engines is the clear trend for the future. The mechanical throttle systems, used for a long time will not fit to the requirements of direct injection. A DC motor for electronic throttle control in conjunction with λ regulation and exhaust gas recirculation are the key elements for low emission cars. Also the automotive ignition system is in a process of change today.

The optimization of the vaporization and mixture formation process is of great importance for the development of modern gasoline direct injection (GDI) engines, because it influences the subsequent processes of the ignition, combustion and pollutant formation significantly. In consequence, the subject of this work was the development of a measurement technique based on the laser induced exciplex fluorescence (LIF), which allows the two dimensional visualization and quantification of the in-cylinder air/fuel ratio. A tracer concept consisting of benzene and triethylamine dissolved in a non-fluorescent base fuel has been used. The calibration of the equivalence ratio proportional LIF-signal was performed directly inside the engine, at a well known mixture composition, immediately before the direct injection measurements were started.

Fuel efficiency and clean combustion engine versus high engine performance - which will increase up to factor 10 in the next 5 years - with less engine displacement are driving more complex engine control systems in today's and future vehicles. The challenge is not only to design a perfect engine, but also to incorporate the right semiconductors. Beside this demand on high sophisticated electronics the demand on cost reduction - especially for small cars - is one driving factor for a smart partitioning. Infineon offers sensors, microcontrollers and power semiconductors for today's engine management platforms and therefore owns the right technologies to manufacture those devices. This opens up the possibility to integrate more functionality in less devices as in today's partitioning or to define electronics to simplify complex control strategies and to optimize the performance of each device.

An innovative way of lowering engine fuel consumption is to reduce engine displacement. However, smaller engines featuring reduced swept volume typically exhibit insufficient torque at low engine speeds. Conventional exhaust turbochargers are not able to compensate for this behavior and additionally suffer from the familiar turbo lag. One possible solution may be an electrically assisted turbocharger, with a high-speed motor providing the extra boost at low engine speeds. A critical factor for the efficiency of the concept is the ratio of the electric motor torque and the rotational mass inertia of the rotor. Testbench evaluation shows acceleration times of 0.5 seconds to reach speeds up to 70,000 rpm. Typically, the electrical load of such systems goes up to 3 kW. Target motors are various types of electrically commutated motors such as BLDC, switched reluctance or induction motors.

A cooperation of several research partners supported by the German Federal Ministry of Research and Education proposes a new active matrix LED light source. A multi pixel flip chip LED array is directly mounted to an active driver IC. A total of 1024 pixel can be individually addressed through a serial data bus. Several of these units are integrated in a prototype headlamp to enable advanced light distribution patterns in an evaluation vehicle.

A local Gaussian process regression approach is presented, which allows to model nonlinearities of internal combustion engines more accurate than global Gaussian process regression. By building smaller models, the prediction of local system behavior improves significantly. In order to predict a value, the algorithm chooses the nearest training points. The number of chosen training points depends on the intensity of estimated nonlinearity. After determining the training points, a model is built, the prediction performed and the model discarded. The approach is demonstrated with a benchmark system and air charge test bed measurements. The measurements are taken from a turbocharged SI gasoline engine with both variable inlet valve lift and variable inlet and exhaust valve opening angle. The results show how local Gaussian process regression outmatches global Gaussian process regression concerning model quality and nonlinearities in particular.

ISO 26262 is the actual standard for Functional Safety of automotive E/E (Electric/Electronic) systems. One of the challenges in the application of the standard is the distribution of safety related activities among the participants in the supply chain. In this paper, the concept of a Safety Element out of Context (SEooC) development will be analyzed showing its current problematic aspects and difficulties in implementing such an approach in a concrete typical automotive development flow with different participants (e.g. from OEM, tier 1 to semiconductor supplier) in the supply chain. The discussed aspects focus on the functional safety requirements of generic hardware and software development across the supply chain where the final integration of the developed element is not known at design time and therefore an assumption based mechanism shall be used.

In modern vehicles, the number of small electrical drive systems is still increasing continuously for blowers, fans and pumps as well as for window lifts, sunroofs and doors. Requirements and operating conditions for such systems varies, hence there are many different solutions available for controlling such motors. In most applications, simple, low-cost DC motors are used. For higher requirements regarding operating time and in stop-start capable systems, the focus turns to highly efficient and durable brushless DC motors with electronic commutation. This paper compares various electronic control concepts from a semiconductor vendor point of view. These concepts include discrete control using relays or MOSFETs. Furthermore integrated motor drivers are discussed, including system-on-chip solutions for specific applications, e.g. specific ICs for window lift motors with LIN interface.

The electrification of the powertrain is still one of the main challenges and innovation drivers for modern cars. With the introduction of the Toyota Prius, launched in Japan in 1997 the first commercially available hybrid car in mass production, the development continued towards the BMW i3 launched in July 2013. One main component for all kind of hybrid cars is still the power semiconductor, which is used for DC/DC converters and for the inverter to drive the electric motor for the traction control. What makes the selection of the right power semiconductor complex, is the variety of different voltage levels within the car (from standard 12V board net, the new 48V board net all the way up to 400V and above) plus different requirements in terms of switching and conduction performance, or accordingly power losses. The selection of device by application and voltage will be discussed in this paper.

Air conditioning acoustics have become of paramount importance in electric vehicles, where noise from electromechanical components is no longer masked by the presence of the internal combustion engine. In a car HVAC systems, the coolant compressor is one of the most important sources in terms of vibration and noise generation. The paper, the generated structural noise is studied in detail on a prototype installation, and the noise transmission and propagation mechanisms are analyzed and discussed. Through ”in situ” measurements and virtual point transformation, the rotor unbalance forces and torque acting within the component are identified. The dynamic properties of the rubber mounts, installed between the compressor and its support, are identified thanks to matrix inversion methods. To assess the quality of the proposed procedure, the synthesized sound pressure level is compared with experimental SPL measurements in different operational conditions.

The use of micro controllers in automotive systems renders the coordination of about 150 actors (70 electric motors, 15 magnetic valves and 50 relays). The resulting complexity of those systems as well as the requested zero defects demands time consuming testing. This work describes a method of performing test-scenarios, starting from a zero defect running specification, modeled by finite state machines. The test-scenarios are intended to determine whether a given system meets all specification requirements. First, a kind of structured modelling reactive automotive systems is deduced. Next, some important test selection methods, developed for the case the specification is given in the form of a finite state machine, are considered. Finally, a procedure and method for performing minimized complete test-scenarios for automotive systems are presented.

In a joint research project between industrial companies and a number of research institutes, nitrogen oxide conversion in oxygen containing exhaust gas has been investigated according to the following procedure Basic investigations of elementary steps of the chemical reaction Production and prescreening of different catalytic material on laboratory scale Application oriented screening of industrial catalyst material Catalyst testing on a lean bum gasoline engine, passenger car diesel engines (swirl chamber and DI) and on a DI truck engine Although a number of solid body structures show nitrogen oxide reduction by hydrocarbons, only noble metal containing catalysts and transition metal exchanged zeolites gave catalytic efficiencies of industrial relevance. A maximum of 25 % NOx reduction was found in the European driving cycle for passenger cars, about 40 % for truck engines in the respective European test.