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The permanently increasing number of convenience and safety functions leads to higher complexity of in-car electronics and the rapidly growing amount of sensors, actuators and electronic control units places higher demands on high- speed data communication protocols. Safety-critical systems need deterministic protocols with fault-tolerant behavior. The need for on-board diagnosis calls for flexible use of bandwidth and an ever-increasing number of functions necessitates a flexible means of extending the system. None of the communication solutions available on the market until now (like CAN or TTP) have been able to fulfill all these demands. To solve these problems, BMW together with several semiconductor companies has developed a new protocol for safety-critical applications in automotive vehicles.

This paper will outline the results of a study performed to analyze the market introduction of x-by-wire applications in the context of weak global industry environment, technological and legislative challenges, standardization issues and end customer benefits. This paper attempts to provide a bird-view on influence factors and impacts for the x-by-wire market, including e.g. the end customer's acceptance and legal environment driving further development in specific areas. Further, major driving forces on semiconductor/component level will be outlined regarding e.g. pin-count, computation performance and heat dissipation, but also possible scenarios and solutions towards safe and efficient system design and partitioning.

A new simulation tool was established and approved by TRW as part of the continuous improvement of the development process. This tool allows the OEM and the system supplier to keep high quality even with further reduced development times. The introduction of the tool in a side air-bag development program makes it possible to ensure high development confidence with a reduced number of vehicle crash tests and late availability of interior component parts.

Automotive powertrain and safety systems under design today are highly complex, incorporating more than one CPU core, running with more than 100 MHz and consisting of several 10 million transistors. Software complexity increases similarly making new methodologies and tools mandatory to manage the overall system. The use of accurate virtual prototypes improves the quality of systems with respect to system architecture design and software development. This approach is demonstrated with the example of the PCP/GPTA subsystem for Infineon's AUDO-NG powertrain controllers.

In studying H2S emissions, it is desirable to have an analytical technique which is rapid, continuous, accurate and easy to use in a laboratory or vehicle exhaust environment. Typically, H2S has been measured using the EPA impinger method with collection times on the order of 1 to 2 minutes. Other techniques have been developed with significantly shorter response times. However, it has been shown that the major release of H2S occurs in less than 20 seconds after a vehicle changes from rich to lean operation. Therefore, it is highly desirable to have an H2S analytical technique with a response time of less than 10 seconds. In this paper, the benefits of use of a chemical ionization mass spectrometer (CIMS) to continuously monitor H2S and SO2, emissions are reported. Using the CIMS technique, the effects of several operating parameters on the release of H2S and SO2 from automotive catalysts were studied.

A joint study was conducted between BMW and Goodyear with the objective of analysing the cause and identifying methods to reduce the structure-borne interior noise in a vehicle driving on rough road surfaces. A vibro-acoustic characterization of the car was performed by measuring the car vibro-acoustic transfer functions and by using a transfer path analysis technique to identify the main suspension parts affecting the interior noise at target frequencies. The vibration transmissibility characteristics of the tire were measured and also simulated by Finite Element in [1-200Hz] frequency range. The vibro-acoustic interaction between the tire and car sub-systems was examined. A Finite Element sensitivity analysis was used to define and build new prototype tires. A 3dB(A) interior noise improvement was obtained with these new tires at target frequencies.

The first part of the paper describes the brake system of the BMW 850i including brake actuation, brake split and ABS. ABS control philosophy and components are presented as well as performance date are shown. The BMW 850i will be available with two Automatic Stability Control systems ASC und ASC+T which are explained more in detail. Special attention is payed to the electronic and hydraulic interfacing of the different sub-systems required for ABS and ASC.

More than ever, microcontroller performance in cars has a direct impact on the driving experience, on compliance with improved safety, ever-stricter emissions regulations, and on fuel economy. The simple microcontrollers formerly used in automobiles are now being replaced by powerful number-crunchers whose performance can no longer be measured in MIPS. Instead, their effectiveness is based on a coherent partitioning between analog and digital, hardware and software, tools and methodology. To make an informed choice among the available devices, what the designer needs are benchmarks that are specific to automotive applications, and which provide a realistic representation of how the device will perform in the automotive environment. This presentation will explore the role of new benchmarks in the development of complex automotive applications.

More than ever, microcontroller performance in cars has a direct impact on the driving experience, on compliance with improved safety, ever-stricter emissions regulations, and on fuel economy. The simple microcontrollers formerly used in automobiles are now being replaced by powerful number-crunchers with incredible levels of peripheral integration. As a result, performance can no longer be measured in MIPS (Millions of Instructions Per Second). A microcontroller's effectiveness is based on coherent partitioning between analog and digital, hardware and software, tools and methodology. To make an informed choice among the available devices, the designer needs benchmarks that are specific to automotive applications, and which provide a realistic representation of how the device will perform in the automotive environment.

This paper presents the objectives and preliminary results of the BRAKE project - a joint effort of Delphi Automotive Systems, Infineon Technologies, Volvo Car Corporation and WindRiver. The objective of this project is to use microelectronics technologies to design a distributed Brake-by-Wire system including: A distributed fault tolerant system for enhanced safety An extension of the OSEK based operating system for a distributed time triggered architecture An open interface between vehicle control, and brake system control The results comprise the requirements, interface specification (see [1]), a full simulation model, a hardware-in-the-loop bench, and a demonstration vehicle. The application has been developed using advanced automatic code generation for Infineon's TriCore based automotive microcontrollers.

For the first time in volume production, supporting welded aluminum structures were used in the chassis area. Metal sheets, extruded sections, longitudinally seam welded pipes and castings were used as semi-finished products. Extensive strength tests, in cooperation with the Design Department and Production, resulted in sophisticated design solutions. In considering matters important to the customer, these solutions were substantiated through numerous examinations which are especially necessary for aluminum.

Trans Tech recently debuted the all-electric eTrans school bus providing a total zero emission school bus. The presentation will demonstrate Smith Electric Vehicles and their history with electric vehicles. The presentation will help ensure that everybody has an idea of what the electric school bus will do and to dispel any rumors about the vehicle. Presenter Brian S. Barrington, Trans Tech. Bus

In order to optimise the vibro-acoustic behaviour of panel-like structures in a more systematic way, accurate structural models are needed. However, at the frequencies of relevance to the vibro-acoustic problem, the mode shapes are very complex, requiring a high spatial resolution in the measurement procedure. The large number of required transducers and their mass loading effects limit the applicability of accelerometer testing. In recent years, optical measuring methods have been proposed. Direct electronic (ESPI) imaging, using strobed continuous laser illumination, or more recently, pulsed laser illumination, have lately created the possibility to bring the holographic testing approach to the level of industrial applicability for modal analysis procedures. The present paper discusses the various critical elements of a holographic ESPI modal testing system.

The number of safety critical automotive applications employing high current brushless motors continues to increase (Steering, Braking, and Transmission etc.). There are many benefits when moving from traditional solutions to electrically actuated solutions. Some of these benefits can include increased fuel economy, simplified vehicle installation and packaging, increased feature set, improved safety and/or convenience, simplified unit assembly and modular testability prior as well as during vehicle manufacturing. The trend to implement brushless motors in these applications (which require electronically controlled commutation) has also brought with it the need for powerful inverters, which primarily consist of Power MOSFETs and MOSFET Driver ICs. This paper reviews the challenges associated with the design of safety critical electronic systems which combine sensing, control and actuation.

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 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.

Functional safe systems fulfilling the ISO 26262 standard are getting more important for automotive applications where additional redundant and diverse functionality is needed for higher rated ASIL levels. This can result in a very complex and expensive system setup. Here we present a sensor product developed according ISO 26262. This sensor product comprises a two channel redundant and also diverse implemented magnetic field sensor concept with linear digital outputs on one monolithically integrated silicon substrate. This sensor is used for ASIL D applications like power-steering torque measurement, where the torque is transferred into a magnetic field signal in a certain magnetic setup, but can also be used in other demanding sensor applications concerning safety. This proposed and also implemented solution is beneficial because of implementation on a single chip in one single chip-package but anyway fulfilling ASIL D requirements on system level.

Integrated Chassis Management ICM is a novel and demanding approach to develop a vehicle chassis and all its control systems in a common process which explicitly addresses the interrelations between them. Primary aims are the improvement of driving safety and comfort by creating synergies in the use of sensor information, hardware, and control strategies. The Electronic Brake Management EBM is an essential part of ICM and an important step to its development.

BMW - the driving force for progress As we approach the new millenium, to ensure the continuation of the progress into the future, BMW uses leading edge approaches in its materials research and processing. Overview production sites all over the world - Plant Dingolfing Quality requirements for automobile painting The complex and wide-ranging demands that the outer skin of an automobile has to meet offered us the chance to advance with a technological leap from liquid clear coat to the potentials of powder clear coat. The new clear coat technology The clear coat creates the ultimate gloss effect - and powder-based clear coat makes the surface of the car even more brilliant. To achieve this effect the body is covered by microscopically small paint particles. A pioneer achievement A lot of challenges in both material development and systems-engineering had to be made. The automotive world was watching, many experts said it could not be successfully used as an OEM clear coat.

Position detection and control is necessary in modern automotive applications because of remotely controlled actuators, such as window lifters or windshield. In recent years, the demand for reliable actuators for safety critical systems, such as power steering systems, has also increased significantly. This creates a growing demand for fast, accurate and efficient servo motor systems that are increasingly smarter, smaller and cheaper. One interesting option is to use Giant Magneto Resistive (GMR) angle sensors to replace the resolvers, Hall, inductive and Anisotropic Magneto Resistive Effect (AMR) Sensors commonly used today for shaft-angle measurements. In principle, there are functional differences among various angle measurement technologies; thus, the effect of switching between them needs to be analyzed.