Customers and various government regulations and requirements have driven the public's need for more functionality in automotive electrical/electronic (E/E) systems, a new challenge for original equipment manufacturers (OEMs) who perform these functions. Of course, the cost of system development and manufacturing is huge, but the challenges that original equipment manufacturers must address are far more than just cost issues, including increasing weight, reliability and quality issues, exponentially increasing complexity, and government requirements. This article refers to the address: http:// From the entire electrical system platform, it has the unique ability to integrate all independent electrical/electronic systems. Consolidation can create unexpected problems that require design modifications. Often these problems are discovered as the design progresses, resulting in a delay in the plan, which misses the deadline and creates costly rework. The increasing complexity and cost of error caused by the number of configurations provided to customers reflects the value of using a system design approach to solve this problem. The system design approach should allow OEMs to maintain product quality, reduce total cost, manage change changes and meet time-to-market objectives. Before we explore how system design can be used to overcome these challenges, let's examine some of these issues in detail. Increased weight and cost of electrical systems Adding cabling and electrical functions to the vehicle can have a significant impact on overall weight and production costs. For example, some luxury cars with more features contain more than 5 kilometers and about 90 kilograms of cable. More wiring weight and cost have forced electrical platform designers to make trade-offs to strike the best balance between cost, weight and functionality. More electronic features mean more complexity The complexity of design and manufacturing increases as electrical/electronic functions increase. In today's vehicles, excess electronic modules provide the functionality required by customers and regulations. These functions are even distributed among a large number of electronic control units (ECUs). High-end cars may have up to 70 ECUs, providing more than 800 functions and interconnected via five system buses. As the number of wires, buses, and functions increases, so does the likelihood of unexpected problems such as potential circuits. In a potential circuit, a special combination of switches and loads can cause accidental operation or failure of electrical functions. The benign consequences of potential circuits are just like the confused drivers, but the more serious consequences include the loss of features that are critical to safety, and even car accidents. Configuration: a nightmare for complexity Although many people are not aware of it, cars have become one of the most complex areas of consumer electronics in the market. This complexity brings the opportunity to configure features in multiple ways. The number of possible configurations of electrical systems has also proliferated as customers are provided with features that increase value and demand, meet safety, reliability, and statutory emissions requirements such as ISO 26262 and Euro 5/6 emissions standards. The number of steps in the electrical design process is multiplied by the number of configurations, as shown in Figure 1. Designers have to face a range of requirements across the platform, passing through several stages; first breaking it down into individual features and then breaking them down into functions that implement them. These features are clustered into the system and then assigned to physical devices or software. Up to 100 million lines of code can be embedded in today's modern cars. The principle design is then associated with the mechanical definition of the entire vehicle and interconnected by a physical wiring system that is finally divided into a series of harnesses. Each platform configuration has its own unique harness that can be split into thousands or even millions of harnesses. Figure 1: This chart shows that increasing the customer's optional features of the car quickly leads to an alarmingly large number of possible configurations. The dramatic increase in the number of configurations affects the entire data flow from requirements to service documents. Once sold, OEMs are responsible for life-long car services. Increasingly, the law requires that such data (specifically, each unique vehicle configuration) be made available to all dealers (not just the original equipment manufacturer network). Manage design changes Previously, each stage of automotive design was an “island†with its own design tools and a complex local language that was used to describe the components, inputs, and outputs of a particular stage. Communication is often cumbersome, requiring conversion and/or manual re-entry of data at each step, resulting in redundancy and latency. These methods are difficult to cope with today's time, cost and competitive pressures. Electrical design engineers need to be able to share information with other engineers and other “islands†to improve communication across teams and departments. They need to be able to more easily understand the environment and impact of change, to implement changes faster, and to reduce misunderstandings. System engineering design approach to better manage complexity Today's cycle times are too slow to compete effectively and meet demand. The process of creating a detailed wiring design from top-down system design is repetitive and time consuming, extending the design cycle by several months. The issues discussed here increase the time between design and manufacturing cycles, and competition increases the pressure to create ideal electrical systems faster. Increasing electrical content, coupled with legal and supply chain challenges, is driving process change. The system design can benefit all parties facing the pressure of modern automobile development. A large body of evidence demonstrates the effectiveness of system design paradigms in managing complexity. Several key features include: holistic, abstract, step-by-step integration, and interconnectivity. Integrity means looking at a problem as a whole, not from a series of isolated activities. In the automotive electrical/electronic design environment, this means connecting various design areas, including a variety of embedded software designs, electronic component design, power distribution system design, and mechanical design. V-shaped chart Engineering design has a fairly standard design cycle. In system design, the design cycle is usually represented by a “V-shaped chartâ€. Figure 2 shows the complete chevron chart, with each step listed. Figure 2: The system design method can be displayed by this V-shaped diagram. A product is first visualized at the top level to generate requirements. These requirements are then broken down into features and functions. The next step is to complete the logic design, and then the physical design without exceeding the platform limits. Then, the component design enters the most detailed level (bottom of the V-shaped diagram). The design is then “rearranged†to integrate printed circuit boards, electronic control units and wiring harnesses into the final product. Faced with increasing complexity, managing designs and changes, and identifying problems early to quickly find low-cost solutions requires a high degree of automation to handle complex problems in a reasonable amount of time. To solve this challenge, a system design approach that combines advanced software can be used to provide digital continuity, requirements tracking, archiving, and design automation, and a comprehensive system V model that covers all phases of the lifecycle. The left side of the V-shaped diagram represents the decomposition of requirements and the creation of system specifications, while the right side represents the integration and verification of parts. With this approach, highly abstracted data is progressively decomposed and enriched until the buildable components (software modules, electronics, harnesses, etc.) are fully defined. These components are then integrated and continuously verified until the entire system is assembled. The transformation of abstraction data can be automated through computer-executable specifications (this process is called synthesis), which maintains full traceability from requirements to component execution. Continuity and automation are the keys to success A software package for implementing system design methods has been introduced on the market, one of which is from Mentor Graphics. This software generates a system engineering example. Software automation that performs system design should provide users with a large number of tools. The necessary features of the software package are described below. Platform level abstraction The software should use a generation method that allows the wiring design to be automatically generated with a high level of input, which is accurate at build time. The software automatically generates accurate routing designs for all platform level configurations (see Figure 3). Figure 3: Through automation, the system is able to complete a logical preliminary design. As the design progresses, the software will continue to "improve" the data. This approach enables manufacturers to master and develop their competitive intellectual property (IP). System integration is fast, and it takes only a few hours to complete tasks that previously took weeks. This reduces the time and cost of electrical design while evaluating alternative architectures. Integrated design environment The software should provide a complete electrical design kit for a larger ecosystem. At the outset, an IT architecture that promotes integration with third-party MCAD, PLM, or ALM tools should be used. Management change Automation should allow multiple levels of abstraction and manage the connections between them so that changes are fully passed. Control and take an intelligent approach to delivering changes to ensure that any value-added work previously done at a lower level of abstraction is preserved. Through tight integration, changes applied to power distribution systems can be coordinated with changes required in other areas to implement changes: effectively coordinate changes, save time, and support concurrent design. Architecture optimization Designers should be able to generate the most detailed harness cost models and related reports to compare the cost of several designs in a matter of minutes (as shown in Figure 4). They can perform detailed and accurate analysis of a wide range of layout concepts in a matter of hours. Fast and accurate trade-offs save the cost per car and reduce the weight of the car. Thousands of times and even millions of electrical designs for different customers are a daunting task, but with these software tools, the thousands of components of a platform project can be optimized and laid out simultaneously. Better and lower cost design. Higher design quality reduces costs and risks. Figure 4: System design software enables easy trade-off comparisons, allowing designers to quickly finalize the best design. Traceable process Users can design process controls to enable verifiable and traceable release processes and design modifications. The software can also use design rules to check for specific constraints. Troubleshoot problems as early as possible Identify problems and provide solutions early in the design process. In this way, adjustments can be made quickly, and the associated costs are much lower than the cost of discovering problems later in the design process. Through simulation, the design can be designed and tested before trial production, so that problems can be discovered early, and in the early stage of design, the adjustment cost is relatively low. The software provides a rigorous failure mode effect analysis to identify issues that may only be discovered by the customer. If the problem is only discovered by the customer, the reputation and profit of the manufacturer will be seriously damaged. Improve data in the design phase Harness development is a turning point in vehicle design and manufacturing. In the online beam development environment, key design data can be transformed into a manufacturable product. The software tool suite supports this process by enabling data continuity, from the earliest design work (getting electrical functional requirements and physical requirements) to the various process stages of implementation. The product to be delivered is a complete wire harness product with detailed documentation. Manage complexity and avoid major losses from recalls and delays Failure to recognize the special effects of electronic/electrical systems can result in serious consequences such as recalls or delays, causing significant losses to manufacturers. For example, the Airbus A380's large jet-type wiring failures that have caused significant economic losses are essentially the failure of mechanical and electrical engineers to manage data continuity and information flow. This worst-case result can be avoided by the integration and verification process on the right side of the system design V model. Implementing a system design approach helps vehicle manufacturers ensure quality and maintain profitability in the future. Mentor Graphics' Capital tools help manage and respond to the ever-increasing complexity and challenges of electronics in the automotive design arena through successful change management through data continuity and design automation across the entire electrical platform.
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