Automotive electronic control units: Inspection design considering time and resources constrains.
Tutor / director / evaluatorLópez Riera, Alexis
Document typeMaster thesis
Rights accessRestricted access - confidentiality agreement (embargoed until 2022-02-09)
On this this document, the state of the art about engine management system inspection will be studied during design and prototyping phase. For this reason, a deep background on automotive sector is needed. Automotive history will be reviewed from the creation of first motorized car up to completely autonomous autopilot, created by Tesla. After that, future trends such as hardware and software modularization will be reviewed. Considering cars high complexity, it is important to have a clear method to coordinate and follow-up vehicle design, not only from OEM (original equipment manufacturer) point of view, but also for its suppliers and sub-suppliers. The most common tool to solve this challenge will be work breakdown structure. Main purpose of engine management system was to assure correct function of vehicle engine according driver inputs. As technology evolves and cars have more electronic components interconnected between them, electronic units have increased in quantity and in functions. In case of engine management system, currently is also taking care of safety related components, like throttle-by-wire, start-stop or tailpipe emissions control. In order to identify possible risks of damage and solutions during product manufacturing, process-by-process analysis will be done. Most dangerous risks are related with incorrect operation of machines, manual operations and mechanical damage to the components caused by hits, as electronic assemblies are very fragile. Basic circuits of the EMS are similar that all control units: power supply, inputs, outputs and communication. After analysing most relevant ones, it is possible to judge critical components to inspect. Available inspection methods will be divided into different categories in order to see possible solutions for each circuit inspection: visual check, either manual or automatic and electronic inspection. As a conclusion, it was found that it is possible to inspect each item using different methods and at the same time, different methods are needed to check all items. Furthermore, it is not possible to develop immutable product, process, system, vehicle, etc. This means that current methods may expire soon, but at the same time, they may be a good starting point for future projects and technologies development.