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S AhmadCentral Electronics Engineering
Research Institute, Pilani
Workshop onEmbedded System in Automobile Industry
Indian Institute of Technology, Mumbai
1st December, 2003
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BARC Presentations
24 April, 2003 2
Introduction
Automotive Industry Quest Passenger Car - Performance Improvement, Reduced Cost, Enhanced Reliability
Conventional Sensor - MEMS Replacement
Newer Possible Applications Earliest Use - Manifold Absolute Pressure
Sensor - MAP - 1979 Silicon Accelerometer - Airbag - 1990s Warranty Period - 10Years/ 150,000 Miles
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BARC Presentations
24 April, 2003 3
Introduction
Improved Fuel Efficiency, Emission and Safety - Federal Standards
Higher Expectations - Performance, Comfort
Greater Availability - Micro-controller, Memory, Display and Enhanced Diagnostics
Very Harsh Under the Hood Environment High Temperature, Shock, Vibration, Humidity, Corrosive Media, EMC and RFI
Military Grade at Lowest Consumer Price
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BARC Presentations
24 April, 2003 4
Automotive Sensor Global Market Growth
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BARC Presentations
24 April, 2003 5
Automotive Sensor Usage Early Estimate - 1997
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BARC Presentations
24 April, 2003 6
Automotive Industry MEMS Sensors
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BARC Presentations
24 April, 2003 7
Product Evolution Time Schedule
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BARC Presentations
24 April, 2003 8
Top Ten MEMS Markets
Micro-fluidic Biochip Glucose Monitoring MEMS Sensor Tire Pressure Sensors Hard Disc Drive Heads Inkjet Print Head Medical Condition Detection Device Large Format Print Head Automotive Function Enabling
Device ABS Accelerometer and Gyroscope Automobile Mass Airflow Sensor
Venture Development Corporation
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BARC Presentations
24 April, 2003 9
Basic Auto MEMS Requirements
Crash Sensing - Air Bag Deployment Vehicle Dynamic Control Rollover Detection System Antitheft System Electronic Parking Brake System Vehicle Navigation System Seat Occupancy / Passenger Position Climate Control Digital Engine Control Road Conditions
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BARC Presentations
24 April, 2003 10
Major Growth Areas
Accelerometer – VDC and Airbags Pressure Sensor – Transmission,
Brakes, Diesel Fuel Rails, Refrigeration, Tires, Fuel Evaporation,Yaw Rates, GPS Backup
Position Sensor – Wheel Speed, Camshaft, Crankshaft, Pedal Positions
Humidity Sensor – Cabin Comfort Distance Sensor – Collision Avoidance
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BARC Presentations
24 April, 2003 11
Airbag Deployment
Acceleration - Continuously Measured Acceleration Exceeds Some Threshold Measured Acceleration Curve Integrated Large Velocity Change - Airbag Fired Steering Wheel and Side Airbag Firing Earlier Sensors - Distributed g Switch Insufficient Information – On/Off Type More Expensive , Less Reliable MEMS Accelerometer - Far Better Gyroscope - ANALOG Devices -
Introduced
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BARC Presentations
24 April, 2003 12
Vehicle Dynamic Control
VDC - Vehicle Skid Control Contains : Gyroscope, Low g Accelerometer,
Wheel Speed Sensor Yaw Rate Prediction - Speed Measurement Gyroscope Measurement - Compared Larger Difference - Single Wheel Brake or
Torque Reduction Applied, Airbag Fired Shock / Vibration Tolerant Gyroscopes - Need ANALO Devices - iMEMS Gyro Better Device
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BARC Presentations
24 April, 2003 13
Vehicle Rollover Detection
More Appropriate - Vans, Trucks, Sport Vehicle Roll Angle and Rate Measurement - Tripping Gyroscope - Roll Rate, Integration - Angle Z - Axis Acceleration – Additional Accelerometer Sideways Sliding Cause Rollover - Curb/Object Dual Axes Low g Accelerometer – Ideal Solution Shock/Vibration Resistant Gyros - Necessary Fast Response Time Gyroscope - Essential
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BARC Presentations
24 April, 2003 14
Security - Antitheft
Vehicle Towing - Popular Type Theft Tilt Detection System - Effective Sensor Pan European Specification - 30 Tilt over
3 minute period - i.e. 0.016o tilt per second
Fluid Tilt Sensor - Possible Use - Limited Tilt Range, Parked Car @ Large Tilt Angle - Sensor Ineffective Harsh Environment - Temperature Change,Sensor Performance Heavily Impaired
Low g Accelerometers – Ideal Tilt Sensor
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BARC Presentations
24 April, 2003 15
Parking Brake System
Manual Parking Brake Activation Robust Push or Pull Type Operation
Braking Force Magnitude - No Concern Electronic Parking Brake - Button
Activation Sensor Measures Vehicle Inclination
Braking Force Requirement DeterminedBrake Applied - Easy Operation
Low g Accelerometers - Ideal Tilt Detection Sensor Sometimes – Single Sensor Used Both Antitheft and Parking Brake Systems
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BARC Presentations
24 April, 2003 16
Vehicle Navigation System
Standard Feature – Luxury Cars Global Positioning System– Fundamental Part GPS - Position and Altitude but No Direction Magnetometer – Early Direction Sensor
Large Ferrous Metal Object - Confused Magnetometer Performance - Not Reliable
Compass and GPS – Initial StartTravel Direction Match - Map Data - DirectionGyroscope - When and How Much Car Turned, Directional Data Match - Map Data
Gyroscope - Heading Information, Low g Accelerometer – Position Data , Integration
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BARC Presentations
24 April, 2003 17
Electronic Engine Control
Intake Manifold Pressure - Air to Fuel Ratio Mass Air Flow Devices - MEMS Version Barometric Pressure - Altitude Information
Rich to Lean Fuel to Air Mixture Decision Cylinder Pressure Measurement - Performance
Optimization - Piezoelectric/ Fiber Optic Sensor Exhaust Gas Re-circulation - Capacitive
Pressure Sensor – Better Solution
Hydraulic Fluid Pressure - Isolated Diaphragm Type Configuration, Sensor – ASIC Integration
Fuel Injection - Silicon Fuel Injection Nozzle
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BARC Presentations
24 April, 2003 18
Sensor Cluster System
Same Sensor Family - Variety of Measurements Accelerometer/Gyros - Sometimes 15 Sensors Difficult Integration, Unsafe Operation Fear Inertial Measurement Unit - Six Axes Inertial
Measurements, Proper location Signal Routing Additional Stand Alone Sensors - Still Required Sensor Cluster Configuration - More Economical
Solution, Better Micro-controller Utilization
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BARC Presentations
24 April, 2003 19
Commercial Off-the-Shelf MEMS Pressure Sensor
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BARC Presentations
24 April, 2003 20
6H-SiC High g Piezo-resistive Accelerometer
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BARC Presentations
24 April, 2003 21
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BARC Presentations
24 April, 2003 22
ARIES Airbag Deployment Test System
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BARC Presentations
24 April, 2003 23
Three Axes MEMS Accelerometer Sandia
Laboratories
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BARC Presentations
24 April, 2003 24
Delphi Automotive System Air Bag
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BARC Presentations
24 April, 2003 25
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BARC Presentations
24 April, 2003 26
Piezo-resistive Pressure Sensor - CEERI
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BARC Presentations
24 April, 2003 27
ZnO Piezoelectric Acoustic Sensor - CEERI
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BARC Presentations
24 April, 2003 28
Polysilicon Load Cell - CEERI
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BARC Presentations
24 April, 2003 29
Three Axes Bulk Micro-machined Accelerometer Test Structure - CEERI
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BARC Presentations
24 April, 2003 30
Sensor Interface ASIC - Schematic
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BARC Presentations
24 April, 2003 31
Sensor Output – Without Conditioning
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BARC Presentations
24 April, 2003 32
Corrected Sensor Output
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BARC Presentations
24 April, 2003 33
Universal Signal Conditioner – Resistive Bridge
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BARC Presentations
24 April, 2003 34
Intelligent Pressure Sensor Chip
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BARC Presentations
24 April, 2003 35
Capacitive Sensor Interface ASIC
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BARC Presentations
24 April, 2003 36
Conclusions
Automobile MEMS Sensor - Fast Growing Multi Billion Dollar Industry Growth Intelligent Sensor Development - Needed Interface and Signal Conditioning - Essential Hybrid Approach - Initial Stage ASICs Use - Commercial ASICS Available Sensor Cluster Approach – Better Solution Already Late Start – Sooner Starting Better
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BARC Presentations
24 April, 2003 37