ecu measurement calibration and diagnostics brochure

7/26/2019 ECU Measurement Calibration and Diagnostics Brochure

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Measurement, ECU Calibration, and Diagnostics Development Solutions for Automotive Embedded Systems


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Contents

1. Introduction 4

2. Applications 7

2.1 Calibrating Automotive Electronic Systems 8

2.2 On- and Offboard Diagnostics 10

2.3 Vehicle Testing 11

2.4 Process Integration 13

2.5 Frontloading 13

2.6 Automation 14

3. INCA Product Family 17

3.1 Measurement and ECU Calibration 18

3.2 Diagnostics 18

3.3 Measure Data Analysis 21

3.4 Simulation and Prototyping 21

3.5 Measurement and Calibration at theTest Bench 22

3.6 Open Interfaces 24

4. Hardware Products 27

4.1 Universal ETK/XETK ECU Interfaces 28

4.2 ECU and Bus Interface Modules 32

4.3 Measurement Modules 37

4.4 Unattended Logging of INCA Data 40

5. Application Engineering Services 43


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ETAS provides development tools for measurement,calibration, and diagnostic (MCD) to automakers (OEMs)and suppliers worldwide. ETAS hardware and softwareproducts form an integral part of the development pro-cess, assisting engineers in everything from developingapplication software for electronic control units (ECUs) tothe integration of automotive electronic systems in thevehicle.

This brochure provides an overview of ETAS MCD productsand their applications. Engineers use INCA and ETAS ECUand bus interfaces along with measurement modules tocalibrate, validate, and diagnose automotive electronicsystems and to acquire reliable data from those systems

and the vehicle environment.

ETAS tools address the requirements of development andtesting applications in the laboratory, at the test bench,and on the road. ETAS products and services encompass awide array of features and benefits:

One-stop shopping for full-system solutions with localexpert support

Comprehensive software tools for advanced applica-tions

Compact-sized, rugged hardware designed for automo-tive environments

Scalable and flexible hardware configurations Support of a wide variety of ECU interfaces

Acquisition of accurate measurement data Open interfaces compliant with automotive standards

ETAS continuously seeks customer feedback and investi-gates the latest technology trends in order to provide themost innovative products for the development and testingdepartments of the automotive and commercial vehicleindustries. ETAS participates actively in the standardiza-tion committees of ASAM, AUTOSAR, FlexRay, JasPar, LIN,Nexus, SAE, and ISO.

1. Introduction


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Figure 1:Requirements for measurement, ECU calibration and diagnostic (MCD) tools.


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Figure 3:Powertrain applications conventional and alternative systems.

Figure 2:Chassis applications driver assistance systems and vehicle dynamics management.


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Electrical and electronic systems comprise a substantialsegment of the feature and function set of modernautomobiles and trucks. The cost efficient implementationof intelligent functions, both within and beyond thedomains of powertrain, chassis, and body, is accomplishedwith the aid of electrics, electronics, and software.

As a function of the rising demands on our automobilesdrivability, convenience, safety, and environmentalcompatibility, the number and complexity of electronicallyimplemented vehicle functions are increasing steadily.Todays midsize cars being equipped with engine andtransmission controls, electronic brakes, occupant safety,as well as driver assistant and infotainment systems,

feature some 40 electronic control units (ECUs). Modernengine control modules process up to 250 MIPS (millioninstructions per second); these may contain upwards of20,000 function parameters. The same magnitude appliesto the volume of code onboard the ECU, the logical coreof all control and diagnostic functions.

Modern automotive systems are interconnected by on-board data buses. The engine management is connectedto the electronic brake. Adaptive cruise control makesuse of position data provided by the navigation system.Hybrid propulsion has to manage engine, transmission,brakes, battery, and electric motor/generator in acombined control approach. New vehicle bus systems suchas LIN and FlexRay have been introduced to provide solu-

tions for low cost or high performance requirements.

INCA offers connectivity to all relevant bus systems. Itprovides for calibrating and diagnosing multiple ECUswhile monitoring bus communication and acquiringmeasurement signals from the vehicle environment. INCAsupports all standard ECU description formats as well asmeasurement, calibration, and diagnostic protocols.

2. Applications


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2.1 Calibrating Automotive Electronic Systems

ECU software is parameterized in such a manner that thebehavior of control and diagnostic functions can be easilyadapted to a variety of system variants or vehicle modelsby calibrating or modifying the characteristic values offunction algorithms, without the need to change calcula-tion routines. Using calibration tools, characteristic valuescan be tuned on-the-fly while at the same time acquiringsignals from ECUs, vehicle buses, and measuring devices.

Vehicle performance is partially determined by the qualityof calibration data. Calibration, i.e., the finding of anoptimized set of ECU parameters for a new vehicle, hasbecome a crucial element in the development of newengines and vehicles. It accompanies the development

process from the first prototypes until after SOP.

A main challenge for calibrating complex ECUs arecontrary requirements, such as NOxversus CO2reduction.In addition, calibrations of electronic systems have tobe done for a number of different vehicles or modelvariants which are sold in the different markets. Notonly do ten thousands of calibration parameters have tobe considered, but also numerous interactions betweendifferent software functions and ECUs must be taken intoaccount. Calibration tasks are normally conducted in awork-split between OEM, ECU-suppliers and engineeringcompanies. The tasks are iterated on different levels ofdetail throughout the development process.

Typical engine calibration tasks for example are:

Optimization of base engine parameters such as injec-tion, ignition, or valve timing with respect to engineoutputs such as power, torque, fuel consumption, andemission under stationary or transient, and cold or hottemperature conditions.

Parameterization of algorithms which derive key en-gine values such as torque, air and fuel mass, tempera-tures, or raw emissions by calculations.

Optimization of idle-control and driveability toachieve the best trade-off between sportiness andcomfort.

Parameterization of correlated safety relevant func-

tions such as vehicle dynamics control. Refinement and validation of calibrations under real-istic and rough environmental conditions during testtrips.

To manage complex optimization tasks, calibrators requiresolutions that combine human expertise with best practiceoptimization methods and easy data handling. INCAoffers sophisticated calibration functions and data man-agement capabilities. In addition, INCA provides interfacesto enterprise data backbones for automating calibrationprocedures. Interfaces enable the integration of INCAfunctionality into customer specific solutions.


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Figure 4:Progress of memory size (in MByte), calibration parameters (number), and cal-culation power (in mega instructions per second / MIPS) bandwidth of enginecontrol units over the period since 1995.


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2.2 On- and OffboardDiagnostics

The need for sophisticated ECU diagnostics onboardthe vehicle is mainly driven by legislative standards foronboard monitoring of emission relevant systems such asOBD and EOBD regulations. Offboard in the service shop,correct and efficient identification of faulty components isessential.

The ODX Open Diagnostic Data Exchange Format declaresonboard diagnostic functions and protocols in a standard-ized manner. The XML-based data description formatenables vehicle manufacturers and their suppliers to main-tain all data of the vehicle life cycle, i.e., development,production, and service data, in a uniform way. ODX wasspecified by ASAM and is published as ISO 22901-1 inter-

national standard. More and more car manufactures andsuppliers support ODX with their diagnostic developmenttool chain.

Comprehensive vehicle diagnostics requires close coopera-tion between ECU and service diagnostics development.When offboard diagnostic functions are developed inparallel to the ECU software, they can be tested at anearly stage of development.

INCA facilitates ECU diagnostics and flash programmingcompliant to the OBD and ODX standards. Being able toexecute software functions and sequences of service tes-ters, INCA provides for the validation of service diagnosticsbefore service tester hardware is available.


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2.3 Vehicle Testing

Laboratory testing of automotive systems is followed byin-vehicle tests. Road testing shifts from initial trials ondedicated proving grounds to public roadways. Standarddrive cycles, e.g., stop-and-go in city traffic, are conductedas well as high-speed runs or tests under various roadconditions. In many cases, to verify performance underextreme conditions of temperature and altitude, vehiclesare subjected to driving tests in Arctic regions, desertareas or high mountain ranges.

Calibration engineers adjust and optimize electronicsystems onboard the vehicle with regard to driving charac-teristics. In addition, thresholds of diagnostic functions areverified against environmental parameters.

Vehicle testing has to be very efficient, since developmentcycles become shorter and the number of test vehiclesis becoming more and more limited. Data has to beacquired throughout the entire vehicle trial to maximizetest coverage.

Drive recorders are an important part of test engineerstool sets. For validation tasks performed within thedevelopment phase, ETAS offers drive recorders thatprovide for unattended operation of INCA functions. Theyreplace the laptop with the INCA software and utilizeETAS measurement hardware, ECU and bus interfaces, andINCA experiment configurations. Vast measurement filescan be recorded and analyzed by use of the MDA Measure

Data Analyzer.


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2.4 Process Integration

Today, the development of complex electronic systemsand their attendant ECU software is an effort which isoften shared by globally acting workgroups coming fromdifferent domains and belonging to different companies.The highly iterative calibration and validation tasks areperformed in various phases of ECU software, system,and vehicle development. They involve calibration andtest engineers as well as function developers, softwareengineers, diagnostic experts, and documentation teams.

Calibrators require comprehensive information on ECUfunctions. In addition to displaying control parameter andvariable values, a calibration tool must be able to handlegraphical representation of software control models,

software engineering documentation, calibration history,bus protocol information and much more. INCA providesall the necessary information at one glance.

For integration with customer processes, existing databackbones and tool environments, INCA provides openinterfaces and off-the-shelf add-ons to the basic product.It offers standard interfaces to test benches and externalapplications such as MATLAB. In addition, INCA comprisesa COM-API interface for programming customized ap-plications.

Calibration artifacts are often stored in dedicatedenterprise data management systems. INCA integrateswith all established systems such as Vector eASEE.cdm,

AVL CRETA, or IAV CalGuide. Calibration projects,work results and progress, as well as access rights can beexchanged between INCA and those systems.

Calibration and validation tasks are subject to increasingpressure on resources in terms of prototype ECUs, testbench sessions, and test vehicles. To meet cost, time, andquality objectives, development processes constantly de-mand efficiency improvements. This leads to the generaltrend of automation and frontloading.

2.5 Frontloading

Every package of calibration work which can be front-loaded from the vehicle to earlier development phasesreduces the need for costly test vehicles, saves valuableengineering resources and helps to locate errors and gapsin the design of vehicle functions at a point in time wherethe effort for correction is still low. The use of advancedsimulation and prototyping technologies facilitatesperforming calibration and validation work in the lab, attest benches, or Hardware-in-the-Loop (HiL) systems, or invirtual environments on the PC.

INCA provides dedicated add-ons for the calibration ofECU function prototypes or simulation models in real orvirtual environments. For ECU testing with a HiL system,

e.g., in a drive simulation, INCA can be used as a measure-ment and calibration server.


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2.6 Automation

Empirical calibration and validation steps are replacedby predefined procedures which can be fully or partiallyautomated. Automated procedures can be performed inmuch shorter time: Error prone tasks can be done moredependably and even complex and critical tasks becomereproducible. Mathematical optimization algorithms andenvironment models support effective automation.

Automation of calibration and validation tasks maycomprise single operations, e.g., ramping up parametervalues, or full tests or calibration runs without any humaninteraction. In the vehicle, calibration procedures whichare repeated many times, e.g., when adjusting gear shifts,are often automated.

At test benches, automation systems control experimentsand perform much of the calibration work. In steady stateexperiments, measurement and calibration tasks are notperformed until the behavior of the unit under test, e.g.,the engine, at a certain working point is stationary. Dy-namic transient state experiments are more realistic andthus improve the quality of measurement and calibrationdata. In addition, they minimize automation cycle times.To perform dynamic experiments, rapid measurementand calibration methods are required. The same is truewhenever control functions such as knock protection areconducted by the test bench instead of the ECU. In thiscase, a real time interface between the test bench and theECU is requested.

ETAS open and flexible MCD solutions support theautomation of measurement and calibration tasks. INCAsupports ASAM as well as real time Ethernet protocols,providing remote access for test bench automationsystems. In addition, application programming interfacesare provided.


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Figure 5:Forecast: calibration efforts will be shifted from the vehicle to the test bench and to the PC.

Figure 6:INCA provides open interfaces for integration with existing processes, data backbones, and tool environments.


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With INCA, ETAS offers a flexible family of softwareproducts for calibration, diagnostics, and validation of au-tomotive electronic systems. INCA is successfully employedin more than 20,000 installations worldwide. It comprisesall functions required by development, calibration, andtest engineers to validate, adapt, and debug ECU applica-tion software. INCA is easy to use and offers user-orientedinterfaces available in English, German, French, Chinese,or Japanese.

INCA is used throughout the development processfrom the initial calibration of a function model, to thepre-calibration of an ECU at the test bench, to the finaloptimization in the vehicle. It is deployed at the desk, in

the lab, at the test bench, and in the vehicle. Applicationsrange from PC simulations to vehicle instrumentation andfrom offline management of calibration data to measure-ment analysis.

INCA supports the full line of ETAS compact hardwaremodules and the powerful ETK/XETK ECU interfaces inmeasurement, prototyping, calibration, and diagnosticapplications. For effortless integration into differentenvironments, INCA offers a wide range of open andstandardized interfaces.

3. INCA Product Family


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3.1 Measurement and ECUCalibration

3.2 Diagnostics

INCA facilitates the adjustment of function parameters,maps, and tables either offline or during ECU runtime.In the course of this, the tool manages the ECUs volatileand non-volatile data memory and resolves parameterdependencies. Powerful editors display scalars, curves,or maps as tables or graphs in physical or hexadecimalformat. Calibration scenarios embrace multiple parametervalues of specific functions and ease the comparison ofdifferent settings.

For offline management of calibration data, INCA offerssophisticated functions for listing, comparing and mergingdatasets. In addition, INCA supports processing of metadata describing the history and maturity of a parameter or

function calibration.

In parallel to calibration, INCA provides for the acquisitionof data from the ECU and vehicle busses such as CAN, LIN,Ethernet, and FlexRay. In addition, INCA measures signalsfrom sensors and the vehicle environment. Quantitiesderived from measurements and calibration variables canbe calculated and displayed online. Data recording may bestarted and stopped by sophisticated trigger conditions.Parallel recording of data related to different trigger con-ditions is possible. Data records comprise measured andcalculated signals, calibration parameters, trigger options,user comments, as well as ECU memory dumps.

ECU diagnostics is added to the measurement and calibra-tion functions by the ODX-LINK complement to the INCAbasic product.

INCA/ODX-LINK acquires calibration and diagnostics re-lated signals in parallel. Both types of signals can be usedfor triggering and calculation of derived signals in thesame manner. All data are recorded in one measurementfile and displayed in the same views. A single ECU and businterface module can provide connections for both, ECUdiagnostics and calibration.

ODX-LINK integrates scan tool functions based on diag-nostic services required by OBD emission regulations. Be-

ing based on the services defined by ISO 15031-5 and SAEJ1979 only, the easy to use OBD scan tool visualizes faultmemory entries, status information of monitoring func-tions, vehicle information, in-use monitor performanceratios, and environmental data known as freeze frames.

Beyond OBD, ODX-LINK facilitates full diagnostics ofECUs compliant to the ODX standard. In addition, INCAcan emulate a service tester and execute troubleshootingfunctions. In this way, service diagnostics can be validatedlong before service tester hardware is available. Alsoincluding a remote-operable ODX-FLASH tool, INCA/ODX-LINK provides a complete solution for validating ODX-based vehicle diagnostics and ECU reprogramming.


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Figure 7:With ODX-LINK, INCA provides a complete solution for the validation ofvehicle diagnostics and flash programming.


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Figure 8:From electronic control units to experimental systems to virtualenvironments on the PC, INCA connects to all kind of targets employedfor simulation, protoyping, test, and production.


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3.3 Measure Data Analysis 3.4 Simulation and Prototyping

In the ECU development process, measurement data thatrelate to different variants of calibration parameter valueshave to be compared. The MDA measure data analyzeris used to visualize, post process, analyze, and documentmeasurements. It provides for evaluating the correlationof diagnostic data with signals from the ECU, sensors andvehicle busses. By use of predefined configurations, mea-surements can be displayed in a uniform manner. By usingthe same views and settings for the same signals indepen-dent of the individual record, similar measurements canbe easily checked against each other. MDA print layoutsare adaptable to corporate design rules and provide for aprofessional documentation of the measurement results.

In the course of simulating, prototyping, or testingfunctions, measurement data often serve as stimuli. MDAis used to select and prepare stimuli signals from rawmeasurement data which was recorded at the test benchor in the vehicle. MDA is capable to process large amountsof measurement data. It supports the MDF file format, anASAM standard which is commonly used by developmentand test tools.

The comprehensive measurement and calibrationcapabilities of INCA can be most beneficially employed inPC simulation and prototyping applications. Simulatingthe behavior of new software functions in a modelingenvironment on the PC is an established developmentmethod. Prototypes are used to validate new functions ina real environment.

Function prototypes can be implemented on differenttargets. As required, they may be executed on an ECU,an experimental system, or a PC. Regardless of thesimulation or prototyping environment that is employed,INCA provides add-ons that establish measurement andcalibration access. INCA-SCX connects to generic simula-

tion environments on the PC using the XCP protocol overTCP/IP connection. INCA-SIP links INCA with Simulink.ETAS INTECRIO facilitates integration of generic C code,Simulink and ASCET models within one prototype. INCA-EIP provides full access to INTECRIO prototypes runningon the PC and to INTECRIO or pure ASCET prototypesimplemented on an experimental system. By using thesame INCA tool at each step, calibration values can beeasily refined.


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3.5 Measurement and Calibra-tion at the Test Bench

For integration with test bench automation systems, INCAsupports the established ASAM interfaces, i.e., the ASAP3protocol and the ASAM MCD-3 MC object model. Thecalibration cycle times that can be realized with thesestandard interfaces are well suited for steady state experi-ments.

Rapid measurement and calibration methods are sup-ported by the INCA-MCE Measurement and CalibrationEmbedded add-on to INCA. By providing real timeconnection of the test bench automation tool to the ECU,INCA-MCE provides for outstanding measurement andcalibration performance.

INCA-MCE runs on the ES910 module serving as realtime ECU interface. Either the standard EtherCAT or theapplication specific iLinkRT Ethernet real time protocolis employed to connect ES910 with the test bench. Usingthese protocols, the automation tool and INCA-MCEexchange measurement and calibration parameters asphysical values addressed by name. To communicate withthe ECU, INCA-MCE transforms all data into the appropri-ate binary values and memory addresses.


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Figure 9:INCA-MCE connects the ECU with test bench automation systems in real time.


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3.6 Open Interfaces

In addition to automation system interfaces, the tools ofthe INCA product family provide a wide range of openand standardized interfaces for configuration, dataexchange, documentation, automation, and integrationwith customer applications.

ECU access is configured by using description files inA2L and ODX format as defined by the ASAM MCD-2standards. Bus communication on FlexRay, CAN, and LIN isdescribed in the respective FIBEX, CANdb, or LDF format.Calibration data are stored in hex formats, whereas sev-eral ASCII formats are supported to exchange subsets ofcalibration parameters. Measure data is recorded in MDFfiles. Being a de-facto standard in automotive testing, the

binary MDF measurement data format is supported bycommonly used data evaluation tools such as MATLABand FAMOS.

INCA provides parameter listings and the results ofcalibration data in XML-format. The configuration ofexperiments and connected hardware also can be docu-mented in XML-files. To provide for interactive access ofparameter and function model descriptions within INCA,an open interface facilitates integration of electronic ECUdocumentation in PDF or WindowsHelp HTML format bythe customer.

For tool integration, INCA offers application programminginterfaces (APIs). The COM-API is based on the MicrosoftCOM (Component Object Model) standard. COM-APIfacilitates remote control of almost all INCA functions andprovides maximum flexibility. Using INCA-MIP, MATLAB

scripts can be employed to automate or semi-automatecalibration procedures. Manual input provided to thescripts by INCA-MIP can be combined with numericalcalculation and optimization routines that utilize the richMATLABlibraries and toolboxes.


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Figure 10:Open interfaces of the INCA product family.


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4. Hardware Products

Figure 11:ETAS hardware products supported by INCA.


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4.1 Universal ETK/XETK ECU Interfaces

The high standards in terms of performance, safety,responsiveness, drivability, fuel savings and emissionsmet by todays vehicles would not be attainable withoutthe deployment of ECUs featuring a multitude of sophis-ticated functions. Powerful measuring and calibrationaccess constitutes an essential prerequisite for developingthese functions and calibrating the function parameters.

The Ethernet-based ETK and XETK interfaces by ETAS pro-vide direct access to the control variables and parametersof an ECU via the parallel data and address bus, or viaa serial microcontroller testing or debugging interface.The ETK/XETK interface is real-time capable. Its dedicatedpower supply enables the preparation and initiation of

cold-start testing independently of the ECU. Due to theirextremely compact design, ETKs/XETKs can be accom-modated inside the housings of production ECUs. They areimpervious to the temperature extremes and vibrations atthe ECUs location in the vehicle.

In contrast to alternative methods which burden theECU program with the task of both data access and datatransfer through a serial interface, an ETK or XETK callsfor very little computing overhead on the part of the ECU.On engine ECUs, for example, large numbers of measuredvalues can be acquired easily without impact on ECUoverhead, even in the presence of high engine speedswith their substantial burden on computing power.

Due to their construction, ETK/XETK development ECUsdo not require an additional serial interface to connectto the development tool. As a functionally and physicallyseparate addition to the ECU, ETKs/XETKs facilitate directcomparison between the behavior of the development

ECU and its production counterpart. Using an ETK/XETKdevelopment ECU, series-production software can becalibrated with great ease and subsequently verified withthe production ECU without the need to change drivers inthe platform software.

ETK-7.1

XETK-T2.1

ETK-S3.0

XETK-V1.0


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Figure 12:Mounting example ETK/XETK-of type VertiCal.


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Figure 13:System with multiple XETK-ECUs and an XETK-ECU with multiplemicrocontrollers connected to INCA.

Microcontroller Type(Manufacturer/Family)

Interface to ETK/XETK ETK/XETK Type Products

Freescale MPC5500 Data and address bus Parallel ETK ETK-P20.0, ETK-11.0

Data and address bus (stan-dardized VertiCal interface)

Parallel ETK/XETK ETK-V1.0, XETK-V1.0

NEXUS interface (JTAG) Serial ETK ETK-S3.0

Freescale MPC500 Data and address bus Parallel ETK ETK-P4.0, ETK-P5.0, ETK-P7.0, ETK-P8.1, ETK-P9.0

NEXUS interface Serial ETK ETK-S2.0

Infineon TriCore Data and address bus Parallel ETK/XETK ETK-T1.1, ETK-T2.1, XETK-T2.1

JTAG interface Serial ETK ETK-S4.2, ETK-S1.1C

Infineon C166, C167 Data and address bus Parallel ETK ETK-7.1

NEC V850 NBD Serial ETK ETK-S5.1

Renesas SH AUD II Serial ETK ETK-S6.0AUD Serial ETK ETK-S1.1D

Renesas M32R JTAG Serial ETK ETK-S1.1B

Various third-partymicrocontrollers

Data and address bus Parallel ETK ETK-7.1, ETK-11.0

Table 1:Overview of ETK types and interfaces for various microcontrollers and microcontroller families from different manufacturers.


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Supported microcontrollers

ETAS provides a broad portfolio of ETKs/XETKs forthe commonly used microcontrollers for engine andtransmission ECUs from Freescale, Infineon, Intel, NEC,Renesas, and STMicroelectronics. ETKs/XETKs are designedaccording to customer requirements, e.g., with regard tomemory sizes and mechanical integration with the ECU.

ETK and XETK interfaces provide long-term stability anddownward compatibility. All of the above add up toa high degree of protection for capital investments inequipment, tools, and training.

ETK and XETK provide Ethernet interfaces to develop-ment tools

ETK and XETK differ in the way the connection betweenECU and host application is set up. ETK-ECUs areconnected to the PC by means of an interface modulewhich provides for protocol handling. In contrast, XETKsimplement a full functional Ethernet interface on boardto facilitate direct connection to the PC. XETKs utilize theXCP-on-Ethernet protocol for data transfer. By use of thisstandard, they can be integrated easily into existing toolenvironments. The XETK is capable of handling up to fourXCP communication channels simultaneously.

This facilitates concurrent access by several PC-based soft-ware applications to an XETK-equipped ECU. Several XETKdata lines can be connected to a host computer through anetwork module. This option is of interest in the calibra-tion of systems which are either distributed across severalECUs or implemented by an ECU equipped with severalprocessors. In such cases, the XETK data of the variousECUs can be reconciled by means of a hardware-basedtime synchronization process.

Full compatibility

ETK and XETK are fully compatible, both in terms of theinterface to the ECU and with regard to the physical

dimensions. Both interfaces are equally supported by INCAand the INTECRIO and ASCET development tools.

Depending on the use case, XETK and ETK, deliver cost ad-vantages. Deploying an XETK eliminates the expenditurefor the PC interface module, whereas the ETK is the morecost-effective ECU interface.


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4.2 ECU and Bus InterfaceModules

The calibration and test engineers ability to measureand calibrate an ECUs control and diagnostic parametersdepends on reliable access to the ECU. ETAS provides com-pact modules that connect the ETK/XETK ECU interfaceas well as the K-Line, LIN, CAN and FlexRay serial buses tothe host PC.

When it comes to the acquisition of a large number ofsignals, the ETK or XETK is the optimum ECU interface.To satisfy more moderate performance requirements,serial calibration protocols like the ASAM-specified CANCalibration Protocol (CCP) or its successor, the UniversalMeasurement and Calibration Protocol (XCP) - which isspecified for CAN, FlexRay and Ethernet physical layers

- are often implemented on the development ECUs. Thecalibration of production ECUs is done on the CAN orK-Line diagnostic interface via a diagnostic protocol suchas KWP2000. Signal monitoring on the vehicle buses LIN,CAN and FlexRay complements both testing and calibra-tion applications.

All compact ECU and bus interface modules are inte-grated within INCA. INCA provides simultaneous supportfor the acquisition of ECU and vehicle bus signals viadifferent modules. Measure data acquired by ES500 orES900 modules from the ECU, the CAN or FlexRay bus aresynchronized by INCA with data from sensors and analogsources. The synchronization enables causal analysis aswell as error tracking. Figure 14 (see page 35) shows the

combined application of measurement and ECU and businterface modules by an example.

ES592

ES585

ES580

ES520

ES510


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Hardware Component ECU and Bus Interfaces PC Interface

ES510 Network Module 3x Ethernet / XETK Ethernet

ES511 CAN and LIN Network Module 2x CAN, 2x LIN, 3x Ethernet/XETK Ethernet

ES512 FlexRay Interface Module FlexRay (2 channels), 3x Ethernet/XETK Ethernet

ES520 FlexRay and CAN Interface Module FlexRay (2 channels), 2x CAN Ethernet

ES580 PCMCIA CAN and LIN Bus Interface 2x CAN or 2x LIN PCMCIA-Slot

ES581 USB CAN Bus Interface 1x CAN USB

ES585 K-Line Interface Centronics 1x K-Line Parallel Port

ES590 Interface Module 1x ETK, 2x CAN, 1x K-Line Ethernet

ES591 Interface Module 1x ETK, 2x CAN Ethernet

ES592 Interface Module 1x ETK, 2x CAN, 2x LIN, 2x Ethernet/XETK Ethernet

ES595 Interface Module 1x ETK, 1x FlexRay (2 channels), 2x CAN2x LIN, 1x Ethernet/XETK

Ethernet

ES910 Prototyping and Interface Module 1x ETK, 1x XETK, 2x CAN, 2x LIN Ethernet

ES920 FlexRay Module 1 FlexRay node with 2 channels ES910

ES921 CAN Module 2x CAN ES910

Table 2:Interfaces supported by the compact ES500 and ES900 modules.

ES920 ES921

ES910


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ES910 offers high computation power

The compact ES910 module is distinguished by its highcomputation power. ES910 lets you easily validate ECUfunction prototypes whether designed in MATLAB/Simulink, ASCET, or coded in C under real-life conditionsin the vehicle. The minimum latency interfaces offer ECUand bus access to the prototyped functions in real time.As an option, the ES910 module can be equipped withES920 or ES921 modules offering a two-channel FlexRaynode or two additional CAN interfaces. INCA provides forcalibrating the functions running on the ES910 simula-tion controller.

At the test bench, ES910 supports time-critical calibrationand validation applications by embedding INCA-MCE. Todo this, the ES910 module converts and transfers data inreal time between the test bed control system and theECU to facilitate automated calibration with short cycletimes.


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Figure 14:Sample setup comprising measurement modules and an ES592/ES595 module acting asinterface to ECUs and the vehicle busses.


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Hardware Component Measurement Channels

ES600 Network Module Connects 6 Ethernet modules to one Ethernet link

ES610 A/D Module 16 x Differential voltage

ES611 A/D Module with Sensor Supply 8 x Differential voltage including sensor supply

ES620 Thermo Module 16 x Universal thermocouple inputs

ES630/ES635 Lambda Module 1 x Oxygen sensor input


ES650 Thermo and A/D Module 8 x Universal thermocouple inputs, 8 x Differential voltage

Table 3:

ES600 Compact Measurement Modules measurement channels.

ES600 ES610 ES611

ES620 ES630/ES631 ES650


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4.3 Measurement Modules

ETAS measurement modules are suitable for in-vehicleand test bench applications where engineers employa multitude of sensors to monitor system and vehiclefunctions. The modules are used for metering electricalpotentials, to acquire voltages, frequencies, or coun-ter/timer signals from active and passive sensors, and tomonitor temperatures as well as lambda, air-to-fuel oroxygen content values.

ETAS provides two series of measurement modulesfor calibration and testing applications. The compactES600 measurement modules are designed for usein the passenger compartment or in the trunk of avehicle. The very small and extra-robust ES400 micro

measurement modules are designed for installationclose to the measurement source. They are well suitedfor applications in the exterior parts of a vehicle, e.g.,under the hood. Combined use is possible for all modulesof the two hardware series. All measurement modulesare integrated with INCA. In parallel with measurementmodules, ETAS ECU and bus interfaces can be connectedto the compact ES600 or ES51x network modules. As analternative to INCA, an ES715 Drive Recorder can be usedto log measurement data.

ETAS measurement modules supply the user withaccurate measure values. Thanks to extremely lowtemperature coefficients and the electrical isolation ofindividual measurement channels, measurement read-

ings are largely independent of ambient temperatureand ground loops.

Network Modules provide for combining measuringdevices to form a cluster and synchronizing them featur-ing microsecond accuracy. Measurement channels behaveexactly the same, regardless whether they belong to onemodule or as part of a device cluster. Based on Ethernet,measurement clusters are capable to transfer high datavolumes to the host application. To optimize each mea-surements time resolution and data rate, each channelfeatures an individually adjustable data acquisition rate.

ES600 Measurement Modules

The metallic housings of the ES600 module family arerugged, compact and easily handled. In standaloneoperation, a measurement module is connected directlyto the PC and to the power supply with the use of a Ysplitter cable. Using a built-in power saving feature, themodules of the ES600 family automatically switch tostandby mode if no PC is connected.

ES600 devices quickly interconnect, simplifying theassembly of a module stack with up to six measurementmodules. The measuring channels in one stack areconnected and time synchronized by a network module.

In addition, the ES600 Network Module supplies powerto each of the connected measuring devices, with themodules being powered up sequentially to prevent loadsurges. The network module continuously displays theactivities on the connecting line to the connected devicesvia LEDs, making it possible to monitor the operation ofboth the module and the connection itself.

In equal measure, ES600 Network Modules provide forcombining and synchronizing of up to six device clusters.One single cable carrying power and Ethernet signalsconnects the PC to the governing network module.Separate clusters can be placed at separate locations,e.g., in the trunk of a vehicle or in the cabin floor area.The star topology tolerates the failure of an ES600

module or cluster and offers easy maintenance of themeasuring setup. In a complex setup, the user can causean identification LED to illuminate in order to spot aspecific module.


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ES400 Micro Measurement Modules

Sensor signals usually require long cable runs to connectwith measurement modules. In the vehicle, this meansrouting heavy cable harnesses through the bulkheadinto the vehicles interior. This wiring technique not onlycalls for extensive modifications of the vehicle body thesubstantial installation and setup efforts also represent asignificant cost factor.

With the measurement modules of the ES400 productfamily, ETAS provides a solution that overcomes the needfor destroying the vehicle body to run sensor cables. TheES400 modules are designed for installation in the im-

mediate proximity of sensors or signals being measured.ES400 module housings are water and dustproof asper IP67 and impervious to acceleration and impact,such as from flying rocks. All connectors are water anddustproof. The modules feature a working temperaturerange of between 40 F and 248 F (40 C and +120 C).

The modules very small form factor facilitates installa-tion even in otherwise unsuitable voids and corners ofthe vehicles engine compartment, body, or chassis. Thisminimizes sensor cable lengths which reduces signal dis-tortion and eliminates long sensor cable harnesses. Onlya single data acquisition cable has to enter the vehiclesinterior through a keyhole.

Established practice with modular test bench concepts isto mount the test candidates on pallet systems, and toset up the required connections with the test bench usingpredefined interfaces. To save valuable test bench time,test objects engines, for example are equipped with thenecessary sensors and measuring modules prior to theirinstallation at the test bench. The arrangement of modulesin close proximity to the sensors and the fact that the datacable represents the only interface to the test bench hostcomputer allows for an easy check of the measurementsetup on the pallet offline. The modules of the ES400 fam-ily are ideally suited to test bench deployment thanks toefficient test preparation plus their immunity to ambientconditions in terms of vibrations, oil vapor, exhaust gas,

and water, which are often present at test benches.

ES400 measurement signals can be accessed by ES715drive recorders. In addition, ES400 modules are fullyintegrated with the ES910 Rapid Prototyping Moduleand provide signals to function prototypes in real time.

By use of the standardized XCP-on-Ethernet protocoland a standalone configuration tool provided by ETAS,ES400 modules can be easily integrated with any third-party applications. A C-based library is available forintegration into software applications that dont provideXCP-on-Ethernet drivers. Currently, ES400 modules aresupported by the applications MM6 from Robert BoschChassis Systems Control, DEWESoft from DEWETRON,

PROVEtech: VA from MBtech Group, and CANape fromVector. Drivers for LabVIEWare also available.


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Hardware Component Measurement Channels

ES410 A/D Module 8 x Differential voltage

ES411 A/D Module with Sensor Supply 4 x Differential voltage, including sensor supply

ES420 Thermo Module 8 x Universal thermocouple inputs


ES441 Counter and Frequency Module withSensor Supply

4 x Counter, timer, or frequency inputs

Table 4:ES400 Micro Measurement Modules measurement channels.

ES410 ES411 ES420

ES430 ES432 ES441


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Alternative to an INCA-PC, the ES715 Drive Recorderprovides for the logging of data from ETAS ECU and businterfaces and measurement modules. For standaloneoperation, the ES715 module contains two onboard CANchannels. Configuration and retrieval of measurementdata is done via an easy to use web interface. The ES715Drive Recorder runs INCA experiments, but can also beoperated if the user is not familiar with INCA. LEDs onthe front panel of the device display the measurementstatus.

The setup of the desired measurement parameters isachieved by the creation of an XML file via an INCAexperiment environment. ES715 mass storage can be

extended by USB memory devices.

4.4 Unattended Logging ofINCA Data

ES650

ES592

ES432

ES600

ES715


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Figure 15:The ES715 Drive Recorder can be connected via an ES592/ES595 Interface Module to multipleETAS measurement and calibration modules.


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ETAS premium engineering services are based on manyyears of experience in automotive electronics develop-ment. Our globally networked experts provide a broadrange of skills. To support our customers in optimizingprocesses, methods and tool environments, ETAS Applica-tion Engineering Services offer training and consulting aswell as development, setup, maintenance, and operationof solutions.

Training

ETAS conducts training at its local training centers or atthe customer site. Courses offered range from standard-ized product training to customized arrangements and

coaching to integration support of new process solutions.

Consulting

Our consultants provide our customers with professionaladvice concerning the efficient use, setup, and migrationof tools.

Customer specific solutions

ETAS customizes software and hardware products andintegrates them into the customer tool environment.Our engineers can develop complete solutions includingproducts from third parties. Upon request, ETAS can alsoinstall solutions on site. Maintenance services ensure the

availability of custom solutions and include adaptations toadditional requirements.

5. Application Engineering Services

Examples for MCD engineering solutions are:

Integration of existing assets such as drive recorders ormeasurement hardware

Setup of cold start measuring systems Construction of ECU signal stimulators

Connection to data backbones Support of specific serial protocols such as GMLAN,

TP2.0 Creation of data converters for proprietary formats

Customization of data visualization and analysisTools for specific purposes such as programming andvalidation of diagnostic sequences

Implementation of customer-specific flash program-

ming

Operations

Following installation at the customer site, ETAS applica-tion engineers are available to provide expert advice tocustomer projects, e.g., during tool migration.

High-value customer solutions complete the ETASportfolio of premium measurement, ECU calibration,and diagnostics products. All ETAS engineers are globallynetworked, service oriented, and focused on our localcustomers.


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Vetronix Corp.

2030 Alameda Padre Serra

Santa Barbara, CA 93103

USA

Phone +1 805 966-2000Fax +1 805 965-3497

[email protected]

ETAS K.K.

Queens Tower C-17F

2-3-5, Minatomirai

Nishi-ku

Yokohama 220-6217, JapanPhone +81 45 222-0900

Fax +81 45 222-0956

[email protected]

ETAS Korea Co., Ltd.

4F, 705 Bldg. 70-5

Yangjae-dong, Seocho-gu

Seoul 137-889, Korea

Phone +82 2 5747-016

Fax +82 2 5747-120

[email protected]

ETAS (Shanghai) Co., Ltd.

24F, Bank of China Tower200 Yincheng Road Central

Shanghai 200120, P.R. China

Phone +86 21 5037 2220

Fax +86 21 5037 2221

[email protected]

ETAS Automotive India Pvt. Ltd.

No. 690, Gold Hill Square, 12F

Hosur Road Bommanahalli

Contact addresses

ETAS GmbH

Borsigstrae 14

70469 Stuttgart, Germany

Phone +49 711 89661-0

Fax +49 711 [email protected]

ETAS S.A.S.

1, place des Etats-Unis

SILIC 307

94588 Rungis Cedex, France

Phone +33 1 567000-50

Fax +33 1 567000-51

[email protected]

ETAS Ltd.

Unit 2A

Meteor Business Park

Meteor CentreMansfield Road

Derby DE21 4SU

United Kingdom

Phone +44 1332 253770

Fax +44 1332 253779

[email protected]

ETAS Inc.

3021 Miller Road

ecu measurement calibration and diagnostics brochure

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