An accelerating market
Car electronics is the fastest-growing electronic market segment in Germany. Most microprocessors and supporting electronics in production there are being used in embedded automotive applications. This is evidenced by the increasing number of PCBs made in Germany in 2006 that became baseboards for embedded car electronics. While PCB production lost market share in many parts of Europe (-13.5 percent in Spain), it rose by 7.4 percent in Germany, 4.8 percent in Switzerland, and 4.6 percent in Austria. Industry experts expect moderate growth in Germany this year, partly because production previously outsourced to Asia is shifting back to Germany to achieve better quality and faster results.
Driverless car stays on track
The Golf GTI 53+1 (Figure 1) from Volkswagen, Germany, is the latest automobile that can drive autonomously along a known road. This experimental vehicle is being used to test and verify antilock braking, electronic skid prevention, engine drag torque control, and other electronic subsystems in cars. A laser scanner and differential GPS navigation system guide the car, which can follow a prescribed driving pattern on a test track marked with traffic cones at maximum cornering speeds. The digital GPS system measures the car’s position with a precision of 2 cm (0.8").
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The MicroAutoBox from dSPACE GmbH, Germany, a leading producer of engineering tools for developing and testing mechatronic control systems, automatically controls the power steering, accelerator pedal, and brake booster. A standard VW Golf equipped with a MicroAutoBox acts as an electronic control unit, conducting repetitive tests under normal road conditions. Calculation software from the University of Hamburg determines the ideal line for attaining minimized steering wheel movement and maximum driving speed/acceleration. This software also determines the optimum braking points, maximum cornering speeds, and other parameters. MATLAB/Simulink is used to develop simulated models of driving situations. The Golf GTI 53+1 is used to test electronic components in a prescribed driving pattern and does not function like a driving robot that can find its own way.
A compact stand-alone box measuring 220 mm x 225 mm x 95 mm (8.7" x 8.9" x 3.8"), the MicroAutoBox uses an embedded IBM PowerPC 750FX at 800 MHz and runs real-time applications like chassis control, power train, body control, X-by-Wire, and other applications. Its many interfaces include CAN, LIN, FlexRay (optional), serial RS-232/K-line/L-Line and others, analog in and out, and lots of digital channels. This allows for easy integration into a wide variety of cars.
Feels like real gear
Porsche has closed the gap between virtual simulation and the actual drivetrain by developing a shift force simulator, which is controlled by electronics from dSPACE running a Porsche simulation model to provide a realistic gear shift feel. This manual transmission sensation is a brand-specific feature with a high recognition factor intended to differentiate the car from the competition, just like the brand-specific engine sound. Static and dynamic effects must be considered in the simulation model. Determining what the shifting quality will be without having any real parts available is possible at various stages of development.
MATLAB/Simulink is used to develop a simulated Porsche model with virtual transmission. The model runs on a dSPACE DS1104 Controller board using a Freescale Power Architecture MPC8240. This board runs the complex Porsche model software and controls the sensors and actors. An enhanced future system will include visualization and sound.
The shift force simulator evaluates the gear stick position, movement speed, and pedal inputs (clutch, brake, and accelerator) and calculates the reaction forces to produce a realistic feel. Independent of real prototype parts, the shift force simulator can be deployed in many configurations. Even ergonomic aspects, like the driver’s position relative to the gear stick, can be adjusted. Porsche uses this simulator to custom develop products for other companies.
Ford is implementing a Ford Fiesta car as a development vehicle for a Micro Hybrid Drive. Ford uses the Fiesta at its research center in Aachen, Germany, to test energy-saving hybrid drives that can reload the battery when braking. A MicroAutoBox loaded with control software (ControlDesk) and application software (CalDesk) also from dSPACE helps achieve optimized results from the Ford Fiesta development car.
