M360

OVERVIEW

Introducing M36O

Pi Innovo OpenECU M360

M360 OpenECU is designed to support high current applications with a favorable functional safety ISO 26262 architecture. M360 is designed with two H-bridges capable of 50 A of transient current. These H-bridges can be used to control brushed-DC Motor automotive applications. Applications include Electric Park Brake (EPB) or Electric Parking Brake (EPB) ECU development.

M360 has a dual-microcontroller architecture with asymmetric hardware and software redundancy.

The high performance MPC5746B microprocessor supported by the powerful 32-bit SPC560P34 secondary microprocessor provides for sophisticated, high-bandwidth rationality checking and system safety monitoring of full-authority vehicle control applications.

Features

  • Powerful dual micro-processor architecture with intermicro serial comms for program flow monitoring and 1x shared external CAN channel from both micros
  • 2x H-bridges for high current outputs (10A continuous, 50A transient for 100ms)
  • Comprehensive fault diagnosis supporting functional safety as well as OBD requirements
  • High level diagnostics fault reporting resident in platform software
  • Platform SW supports light-duty J1979/KWP2000/UDS 14229 and Heavy-duty J1939 service tool interfaces
  • Supported platform software: OpenECU-FS

High Performance 

  • Powerful dual micro-processor architecture with inter-micro serial comms for program flow monitoring and 1x shared external CAN channel from both micros
  • 2x H-bridges for high current outputs (10A continuous, 50A transient for 100ms)
  • Comprehensive fault diagnosis supporting functional safety as well as OBD requirements
  • High level diagnostics fault reporting resident in platform software
  • Platform SW supports light-duty J1979/KWP2000/UDS 14229 and Heavy-duty J1939 service tool interfaces

Capabilities

  • Designed for high current brushed-DC motor control applications
  • Adopted in functional safety and high transient current applications such as Electronic Park Brake
  • Supports common calibration tools such as ATI Vision, ETAS INCA, and Vector CANape via CCP
  • Proven hardware for prototyping, pre-production and volume production

Hardware Specifications

Primary Processor MPC5746B
Secondary Processor 32-bit
Input Pins 4 Analog inputs
Output Pins 4 (2x H-Bridges)
H-Bridge Output Continuous: 2x (10A), Transient: 2x (50A) for 100 ms
Current Monitors 2x current monitors per H-bridge for circuit, rationality and unintended actuation diagnostics - read by both micros
Voltage Monitors 2x voltage monitors (one on each arm) per H-Bridge for circuit and rationality diagnostics - read by both micros
External Communication 1x CAN (both micros have independent interface to the CAN bus)
Internal Communication 1x UART serial interface between the micros
Dimensions 207mm x 104mm x 45mm (W x D x H)
EMC Designed for DIN/ISO 11452, ISO 7637-2 and CISPR 25
Enclosure Aluminum
Weight 0.54kg
Connectors 1x23 TE (AMPSEAL)
Vibration IEC 60068-2-64
Environmental Protection IP69K & IPx8 Sealed/Gore vent

APPLICATIONS

M360 Applications Include:

Application Description
Electric Parking Brake M360 can be used as Electric Parking Brake (EPB) ECU replacing traditional mechanical parking brakes. The M360 as an EPB can control actuators to provide parking brake function and also dynamic braking as a secondary braking system.
High Current H-Bridge Module With 10A continuous and 50A peak (or transient) current H-Bridges M360 can be used in applications to control motors

BLOCK DIAGRAM

This is a default configuration, optional configuration available, please contact us.
For a full list of downloads click here.

CASE STUDIES

Design of Custom Electric Park Brake (EPB) Soluction

Problem Statement

An OEM developing Plug-in Hybrid Electric Vehicle (HEV) identified the need for a new Electric Park Brake (EPB) solution for its next generation of production vehicles. Pi Innovo was selected to deliver an EPB ECU solution leveraging OpenECU platform. Pi Innovo was responsible for ECU hardware development, design and integration of the application software using our rapid prototyping OpenECU software platform.

Pi Innovo was also responsible for executing production and functional verification and testing in accordance with ISO 26262. The highest safety goal for this Custom ECU project was rated to ASIL D as per the customer's Hazard Analysis and Risk Assessment (HARA) and Functional Safety Concept (FSC). The VDA 305-100 standard for Recommendation for integration of Electric Parking Brakes control into ESC Control Units was referenced as a guiding document.

Electric park brake EPB for Motor-on-caliper

Electric Park Brake (EPB) architecture

What is an EPB?

An Electric Park Brake (EPB) for automotive applications requires a park brake actuator to generate force on the brake disc to hold the vehicle in place, and an Electronic Control Unit (ECU) to provide power and control to the actuators. An EPB is typically used to replace the park-pawl functionality of an automatic transmission, and a mechanical handbrake’s emergency braking functionality.

Electric Park Brake (EPB) with M360

ISO 26262 Functional Safety

To develop this product in accordance with ISO 26262 for an ASIL D item. Pi Innovo follows the ISO 26262 V-model as shown. Pi Innovo was responsible for authoring the work products specified in ISO 26262 parts 4, 5, and 6.

  • Part 4: Defines product development at the system level
  • Part 5: For hardware level, and
  • Part 6:For software level

Functional Safety V-Model Process

Custom System Development

In accordance with ISO 26262 Part 4, system-level analysis was performed to ensure a safe system was designed.  One purpose of the Part 4 work products is to identify all failure modes of the system and ensure a diagnostic or safety mechanism is in place for each failure mode.  Functional safety process from Pi Innovo Custom ECU offering includes the following:

  • Fault Tree Analysis (FTA) against the Technical Safety Requirements
  • Dual Point Failure Analysis (DFP) and
  • Design Failure Mode and Effect Analysis (DFMEA)

ISO 26262 (Functional Safety) Part 4

After the analyses were completed, an Item Integration Test Plan (IITP) was derived to define test objectives and methodology as it relates to testing the Hardware-Software Integration (HSI). Examples of ISO26262 Part 4 Work Products composed during this program include the following:

  • Technical Safety Requirements and Concept
  • System Design Specification
  • Item Integration and Testing Plan, Specification, and Report
  • Product Verification Strategy
  • Fault Tree Analysis (FTA)
  • Dual Point Failure Analysis
  • System FMEA
  • Hardware-Software Interface Specification
Custom Hardware Development

Hardware development for this program included creating a custom enclosure and Printed Circuit Board (PCB). Pi Innovo’s long standing history of development of Custom ECUs was heavily relied upon for developing a dual-micro-controller architecture to support high ASIL ECU as per the ISO 26262 process meeting the safety goals of the item.

EPB hardware design

Additional features developed for this program include:

  • High current H-bridge drivers
  • Protection circuitry and
  • EMC mitigation circuits.

Design and Verification Testing (DV Testing) and Production Validation Testing (PV) were performed to verify the hardware was developed to ASIL D.

Examples of ISO26262 Part 5 Work Products composed during this program include the following:

  • Safety Plan
  • Hardware Safety Requirements Specification and Verification Report
  • Dependent Failure Analysis
  • Hardware Safety Analysis and Report
  • Hardware Design Specification and Verification
  • FMEDA

 

Custom Software Development

To achieve ASIL D, a design choice was made to decompose the ASIL D software into two B(D) microprocessors: Primary and Secondary microcontrollers.

The Primary microcontroller software contains the park brake supplier's application source code as well as Pi Innovo’s HOST application code, developed with the OpenECU platform.

In addition to park-pawl, park brake, and emergency braking functions, the application also uses the OpenECU diagnostics library to set and store trouble codes for UDS (Unified Diagnostic Service) diagnostic tools and send information to the vehicle HMI for driver notification.

The Secondary microcontroller acts as a safety barrier to the Primary micro by independently reading all the safety-critical signals of the system.  It will prevent the HOST micro’s actuation commands if it independently detects an unsafe scenario.

The OpenECU platform and the application software for both microcontrollers were designed in accordance with ISO26262 Part 6.

Software features are developed in four steps:

  • Software Architecture Design
  • Low Level Requirements
  • Code Implementation, and
  • Software-in-the-Loop (SIL) testing.

Examples of ISO26262 Part 6 Work Products composed during this program include the following:

  • Safety Plan
  • Software Verification Plan, Specification, and Report
  • Design and Coding Guidelines
  • Tool Application Guidelines
  • Software Safety Requirements Specification
  • Safety Analysis Report
  • Software Architecture Design Specification
  • Dependent Failures Analysis Report
  • Software Unit Implementation and Design Specification
  • Embedded Software

 

Multiple-Supplier Collaboration

The VDA 305-100 Recommendation for integration of Electric Parking Brakes control into ESC Control Units provides guidelines for collaboration between multiple suppliers. The standard assumes that one supplier is responsible for the park brake assembly and its control algorithm while the other is responsible for the ECU and unit functionality software.  It also differentiates the two parties as “PBC” (Park Brake Control) and “Host”. Pi Innovo served as the Host in this program and was responsible for allowing the PBC access to software and hardware components of the EPB ECU.  The PBC was designed and developed by a third party partner.

The Host software acts as a mediator between the PBC and the Hybrid Control Unit (HCU) and Electronic Brake Control Module (EBCM) and other components on the CAN bus. The Host is also responsible for driver alerts for fault conditions (over CAN) and setting diagnostic trouble codes.  Other responsibilities of the Host include standstill manager, which is used to track the vehicle state (static or dynamic) and handle "apply" and "release" requests from the vehicle or driver.

Also, using the H-bridges to drive the park brake actuators as requested by the PBC and to provide voltage and current feedback are also responsibilities of the Host.  Last, the Host is responsible for managing UDS requests, which includes relaying service routines to the PBC.

Hardware and Software Challenges

The two-microprocessor architecture of the EPB posed unique challenges in development.  Software development was challenging because the microprocessors required freedom from interference from each other.

To accomplish this, the primary application software was developed using the OpenECU model-based suite while the secondary application was developed in hand-code C. Different compilers were used for both micros in order to ensure safety from common cause failures that may result from same tool-chains.

Results

EPB Custom ECU block diagram

  • Requirements Documentation
  • Functional safety plan
  • Software prototype delivered in 5 weeks
    • Application Software included
  • Delivery of hardware prototype in 4 months
    • A-Sample
    • Design Verification Plan (DVP&R)
    • B-Sample Controllers

Pi Innovo produced a functioning hardware prototype of the ECU within four months of the project start date and a software prototype was available in five weeks. Allowing the brake actuator supplier to begin calibration early in the program. Pi Innovo has supported the customer on this program for over two years.

Tools Used
  • MATLAB-Simulink
  • OpenECU
  • M360
  • UDS
  • OBD-II
  • CodeWarrior IDE
  • Wind River DIAB
  • VectorCast

Keywords: EPB, Motor-on-Caliper, Functional Safety ECU, High Current ECU, M360

 

DOWNLOADS

To view the complete list of our product downloads, please click here.

MODULE
COMPARISON

Compare ALL OpenECU Modules

Primary Processor SPC5534 MPC5534 MPC5534 MPC5534 MPC5674F MPC5746B SPC5746 SPC5746
Primary Clock Rate 80MHz 80MHz 80MHz 80MHz 264MHz 160MHz 160MHz 160MHz
Primary Code Space 512KB 768KB 768KB 512KB 3MB 2302KB 3MB 3MB
Primary RAM Space 64KB 832KB 832KB 64KB 128kB 384KB 256KB 256KB
Primary Calibration Space 256KB 236KB 256KB 256KB 128kB 128KB 256KB 256KB
Secondary Processor SPC560P34 SPC560P34 SPC560P34
Secondary Clock Rate 64MHz 64MHz 64MHz
Secondary Flash Space 192KB 192KB 192KB
Secondary Calibration Space 20KB
Secondary RAM Space 12KB 12KB
Operating Voltage 9V to 32V 7V to 32 V 7V to 32 V 12V or 24V 8V to 18V 8V to 18V 8V to 18V
Sensor Supply 1x 5V @250mA 1 x 5V / 250mA 1 x 5V / 250mA 2x 5V@250mA 4x 250mA @ 5V none 2x 5V @200mA 2x 5V @200mA
Standby Current 0.25mA @12V 0.25mA @ 12V
Actuator Supplies 1x 20A 2x 10A @ Vbatt
High Speed CAN 2.0 2x 2x 2x 2x 4x 1x 4x 4x
Inputs (Analog or Digital) 10x 9x 16x 18x (Digital: 6x; Analog: 12x) 40x (Digital: 5x switched, 3x Frequency, PWM; Analog: 32) 4x 40x (Digital: 9x switched, 3x PWM; Analog: 28) 44x (Digital: 9x switched, 3x PWM; Analog: 32)
Reprogramming Enable (FEPS) 1x @ -18V 1x @ -18V 1x @ -18V 1x @ -18V 1x @ -18V 4x
Differential VRS 1x (2 pins)
Single Ended VRS 2x
Frequency 1x
Cam Shaft 2x ±157V 4x Hall only
Crank Shaft 1x ±157V 1x Hall (VR option)
RTD Sensor 7x 4x
Knock Sensor Knock Sensor
Lamda Sensor (UEGO) 2x
Lamda Sensor (HEGO) 4x (only 2x available when using 2x UEGO)
Ignition Sense 1x 1x
Low Current Low Side Drives Up to 1x 20mA & 2x 100mA & 6x 500mA 12x 100mA, 3x 400mA, 14x 700mA, 2x 1A 11x 100mA, 4x 400mA, 14x 700mA, 2x 1A
Medium Current Low Side Drives Up to 4x 2A
High Current Low Side Drives 4x 2.2A, 1x 3.2A 4x 2.2A, 1x 3.2A
0-5 V Analog Output Up to 2x 10mA
PWM Low Side 2x 100mA 2x 100mA, 2x 250mA & 6x 2A
H-Bridge 1x 5A 2x 8A 1x 5A full-bridge & 2x 10A full-bridge or 4x 10A half-bridge 2x 50A peak or 10A 1x 10A, 2x 5A, 1x 3.2A 1x 10A, 2x 5A, 1x 3.2A
High Side Switch 1x 15A 1x Hall (VR option)
Low Side Injector 1x 15A or 5A 3x 5A peak/ 2A hold 8x software-programmable waveform peak-and-hold: nominal 25A peak, 15A hold
Current Monitors 2x
Voltage Monitors 2x
High Side Logic Outputs 2x 1mA 2x 1mA
High Side Outputs 4x 700mA 4x 700mA
Low Side General Purpose, PWM (SM, VM, CTM) 1x 10A, 1x 2A, 1x 500mA 9x 0.2/0.5A lamp & relay, with monitoring of state, voltage, and fault status
Low-side General Purpose, Spark (SM) 1x 8A 8x (Smart Coil only) with monitoring of state; on-off mode for non-spark uses
High-side Injector sources 2x Injector High-Side outputs with programmable boost voltage phase, 25A peak
Low side GP (General Purpose) (VM, CTM) 1x 8A, 2x 6A peak / 4A hold, with voltage and current-tripped monitoring
High-side GP (General Purpose) (CM) 2x 8A up to 85°C, intended for source to low-side outputs, with current monitoring
Constant-Current (with inductive actuator) 8x 2A
Vibration ISO 16750-3 6g random RMS 6g random RMS Ford IIIB - Severe ISO 16750-3 IEC 60068-2-64 ISO 16750 chassis mount ISO 16750 chassis mount
Environmental Protection IP67 - Sealed IP67 IP69K IP67 Sealed/Gore vent IP69K IP69K & IPx8 Sealed/Gore vent IP69K Sealed/Gore Vent IP69K Sealed/Gore Vent
ESD ±8kV - SAE J1113-13
Conducted and Radiated Emissions CISPR25 Class 2
Conducted Transients ISO 7637-2
Bulk Current Injection Immunity ISO 11452-4
Material Plastic (PPA GF33) Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum
Dimension in mm (W x H x D) 138 x 130 x 42 155 x 115 x 46 155 x 115 x 39 228 x 158 x 50 266 x 299 x 56.5 207 x 104 x 45 225 x 205 x 45 225 x 205 x 45
Weight 520g 520g 1.02 kg 2.5 kg 540g 1.1 kg 1.1 kg
Connectors 2 x 20 pin (Molex MX-150) 46 pin 46 pin 46 pin Molex CMC 154-pin, 3-pocket 1x 23 TE (AMSEAL) Molex 112pin (1x 48, 2x 32) Molex 112pin (1x 48, 2x 32)
Location Chassis mount Chassis mount Chassis mount Engine Compartment/ Chassis Engine Compartment / Chassis Passenger Compartment Chassis/Passenger Compartment Chassis/Passenger Compartment
Operating Temperature ISO 16750-4 (-40°C to 85°C) -40°C to 85°C -40°C to 85°C -40°C to 85°C -40°C to 85°C -40°C to 85°C -40°C to 85°C -40°C to 85°C