GEMS-K1 ECU hardware design Document_V0.3

GEMS-K1 ECU hardware design Documentv 0.3 14nd Sep 2008GEMS-K1 ECU hardware design DocumentTianjin UniversityInfineon Automotive Electronic Joint LaboratoryAuthor: NengHui Zhou- 60 of 60 -TJU-IFX Joint LabRevision historyVersionByModificationsV0.1, 14st Aug 2007Nenghui ZhouFirst draftV0.2, 18st Jan 2008Nenghui ZhouAdd the contents (3.63.8, 79)V0.3, 14st sep 2008Nenghui ZhouUpdate the document after finishing the 2nd HW，Attention please!This document is only for internal use in the GEMS-K1 project. Tianjin university Infineon Automotive Electronics Joint Lab 2008.All Rights Reserved.Content1.General description of ECU hardware42.Hardware design Requirements43.Differences between 1st version and 2nd version64.ECU configuration and each modules function64.1 Microcontroller module84.2 Power supply module154.3 Input signal conditioning184.4 Crank and Cam signal conditioning184.5 Ignition module194.6 Low side switch module214.7 ETC module254.8 Serial Communication module (CAN and KWP)295.Designed for reliability345.1 Protection and diagnostics at Inputs345.2 Protection and diagnostics at Outputs356.Components list of the ECU417.Connector Pin Assignment of the ECU448.PCB layout479.Hardware evaluation and test5110.Appendix5210.1 Schematic521. General description of ECU hardwareThis ECU is designed for four cylinders gasoline engine which based on infineons 32 bit microcontroller, power unit and other components. It can receive signals from sensors, process them with software, and then transmit the converted controlling messages to actuator so as to fulfill the target of controlling the injection and ignition and so on. When the engine management system has faults, this ECU can self-protect and diagnose the faults position and type, store the fault codes in ECU for maintenance and communication with other equipments via KWP2000 and CAN bus protocol. This ECU is a full reference design which can meet the need of different gasoline engines and customers.2. Hardware design RequirementsGEMS-K1 ECUs hardware design must have high level requirement as fellow:1. ECU based on TC17662. Monitor and fail safe based on PCP ( inside TC1766 )3. 4 cylinder4. 4 On board IGBTS (drive with only 2 or 4) or 4 discrete EST (for external smart pencil coil).5. ETC control with optional ISCV6. VVT actuation7. Stepper Motor option for cable/spring driven throttle blade control8. VR crank interface/option for Hall interface 5V or 12V pull-ups.9. DSP knock filter (reuse PSK interface )10. 2 lambda and heaters (normal)11. Charcoal Canister Purge12. Cooling Fan( by relay)13. Fuel Pump ( by relay)14. Air conditioning (relay)15. Single CAM phase on intake16. 5V sensor interface by level shifting to 3.3V17. 4 layer FR4 PCB provision of mounting with spacers or onto casing18. Ambient temperature -40 to 105C continual operation19. Able to be protected against static voltage of 24V for a duration of 1 min 20. Reverse battery protection with standard car battery potential for a duration of 1 min21. All ECU I/O connector pins except supply and GND pins are to be protected against short to ground and Short to battery scenarios.22. All sensor Inputs have default operation in case of fault.23. All load inputs and outputs have diagnostics in case of fault (except Diagnostic lamp 1, 2, and engine speed but protection is needed for their driver.)24. All inputs signal conditioning must be able to cope with transient operations and the frequency of voltage change. Low/ pass filters used in signal conditioning should not attenuate the voltage value in the operating range of the sensor inputs25. All ECU pins must have bypass caps consideration to protect against ESD (SAEJ113-13 direct contact discharge +/-10KV, Airgap discharge +/-18KV).26. ECU must be able to pass load dump scenario of 80V for a duration of 400ms(the rise and fall time of this 80V peak is within the duration of 400ms.27. There must be a circuitry implementation regardless with on-chip or with discrete solution to allow TC1766 to detect the coil current.28. ECU must make provision of a pin from the connector that could be pulled high/low for ease of diagnostic with lamp29. ECU must have three operation mode. (mode= application/functional/manufacture test). 30. ECU able to accept two pedal position signals31. Size of ECU ( together with casing ) should be of the same size or smaller than a existing 4 cylinder controller in the market32. ECU must make considerations to pass the various tests mentioned in the Hardware test checklist. (for those that are not mentioned here)33. Supply pins of ICs, regardless of voltage value, should be considered to have decoupling caps to handle voltage dip senarios during sudden drawing of current.34. ECU will operate normally for Battery voltage 6V18V.35. Can Bus line to be ESD protected.36. LIN BUS line to be ESD protected too.37. ECU able to fulfill power moding.38. All outputs off in reset mode (except two diagnostic lamps is pull-up to turn on for quick lamp check).39. During the state of IGN Key off, the Leakage current from battery to ECU must be 1mA.40. Immobilizer can be SW bypassed.41. Due to 5V supplied sensors being used with the 3.3V ADC of the TC1766.The 5Vuref 1 and 2 must be measured and taken into account.42. For the ADC inputs going to the TC1766, due to auto-scanning beginning with AN15 thru AN0 (using group1 as example), it is advisable to put critical/high priority signals from AN15 downwards to AN0.43. MSC and GPTA connection are to be hardwired to the concern pins of TLE8710.This provide the capability to compare the operations by MSC and GPTA.44. ETC driver has two enable pins (namely /ABE and DIS pin). One to be connected to PCP commanded I/O pin and another by main micros I/O. Please note that the /ABE3. Differences between 1st version and 2nd versionDifferences between 1st version and 2nd version were shown as follows: 1. The footprint of U901 was wrong. Revised.2. The net of TRCLK was wrong that cause the net of TRCLK is not integrated. Revised.3. The position of connector is not good. Revised.4. The number of C1040 should be 100nF. Revised.5. 1.5V LED indictor cant light because its voltage is too low.It uses 5V to dive the LED and 1.5V for control the transistor. Revised.6. The footprint of c1038 is wrong, should be 0805. Revised7. There are some problems about IGN drive. There should be 3-state output to re-drive IGBT. Used MC74ACT125.8. R802 and R803 should be option. Revised.9. The SO and SI PINs of TLE8104 are reversed. Revised.10. There are two devices SO pin which is connected with micro. So the resistor is to reduce the voltage need only one. Revised.11. The pin35 0f TLE7368 should be connected with battery, or else the micro cant control this chip.12. The pin10 0f TLE7368 was added pull down resistor. (Turn on threshold is 2.0V; the Turn off threshold is 0.8V).13. The MIL light is too complex; Now General Purpose Transistors was used to replace the Digital Transistors. So the SCB protection is very simple.4. ECU configuration and each modules functionECU configuration is designed for gasoline engines control and it is based on infineons microcontroller TC1766 and power semiconductors. The whole ECU is divided into nine modules: microcontroller module, power supply module, ETC module, IGN drive module, serial communication module, lambda & knock module, signal conditioning module, cam & crank signal conditioning, low side switch module (include injector drive, relay drive and solenoid drive). The GEMS-K1 ECU block diagram is to be shown in fig.1.Fig 1: GEMS-K1 ECU Block Diagram4.1 Microcontroller moduleFig.2. block diagram of TC1766The block diagram of TC1766 microcontroller is showed in fig.4. The microcontroller is the heart of the system. Its internal bus runs at 40 MHz generated by multiplying an external 15 MHz crystal in the Clock generator. The microcontroller has two processors: one is High performance 32-bit super-scalar TriCoreTM V1.3 CPU, another is 32-bit Peripheral Control Processor with single cycle instruction (PCP2). And it has 1.5MByte embedded program flash with ECC, 32 KByte data flash for scalable EEPROM emulation, 76KByte on-chip SRAM, 8 KByte instruction cache, 16 KByte Code Scratchpad Memory. High performing triple bus structure (64-bit local memory buses to internal flash and data memory, 32-bit system peripheral bus for interconnections of on-chip peripherals and further functional units and 32-bit remote peripheral bus serving the requirements of high speed peripherals) ensures fast access between the core memory and peripherals.There are a number of peripherals used in the ECU design. The 17 channel 10 bits ADC (programmable to 8 or 10bits) is used to read analog inputs like TPS, Engine Block Temperature, Battery Voltage, Ignition Voltage and MAP. Analog input range is 0-3.3V at nominal speeds of 1.9usec per conversion and the external input voltage is lowed down or clamped before these signals are inputted. The ADC supports a few modes of conversion. The one use in this design is the auto scan continuous. This means the analog inputs are sampled sequentially and a few samples are converted and averaged. In this design some of the spare ADCs were used as inputs (fault status) from the smart drivers.The engine position and CAM signal after filtering and converted to logic 0-3.3V levels by the interface is fed to the GPTA module. The filter and prescaler cell, duty cycle measurement and limit checking cell and digital phase locked loop cell used to detect crank & cam signals and calculated engine position, speed and micro tick. These signals generate interrupt and in turn generate the injector and spark signals. Injector pulse widths and spark dwell time /advance are added depending on engine position, temperature, battery voltage and BAP. Therefore, the GPTA module is used to the drive signal of ETC, VVT, lambda heater, CPV and so on.Other signals (such as A/C switch, cruise switch and faults detected) are also inputted into GPTA module. This is a capture and level reading function used to detect signals. The edge detected generates an interrupt and in turn generates hardware protection or faults detecting. Or the input level is read periodically and makes certain the station of input signals.Serial communication between the micro and some smart drivers are done via the SSC (High speed synchronous channels). This allows the micro to control and read diagnostic status of the smart drivers. The communication used the SPI protocol and the micro is assigned as master. This design uses SSC0 and SSC1.To communicate with the power devices (TLE8710), the MSC0 (Micro Second Channel) module is used.To communicate to the outside world for OBD data transfer by K line, the ASC0 (asynchronous/synchronous channel) is used. And ASC1 is used for immobilizer.The microcontrollers pin assignment is shown in table 1: Pin numberPin NameGEMS-K11GPTA40/P5.0cruise switch2GPTA41/P5.1A/C pressure switch3GPTA42/P5.2A/C switch4GPTA43/P5.3diagnosis request5GPTA44/P5.4vehicle speed input6GPTA45/P5.5spare digital input7GPTA46/P5.6RS232 ready signal input8GPTA47/P5.7KWP Enable9TRCLKTRCLK10VDD1.5V11VDDP3.3V12VSSGND13TDATA1/P5.8TDATA114TVALID1/P5.9TVALID115TREADY1/P5.10TREADY116TCLK1/P5.11TCLK117RDATA1/P5.12RDATA118RVALID1/P5.13RVALID119RREADY1/P5.14RREADY120RCLK1/P5.15RCLK121NC.NC.22VSSAFGND23VDDAF1.5V24VDDMF3.3V25VSSMFGND26VFAREF3.3V27VFAGNDGND28AN35Knock_229AN34Knock_230AN33Knock_131AN32Knock_132AN31NC.33AN30NC.34AN29NC.35AN28NC.36AN7TPS_237AN27NC.38AN26NC.39AN25NC.40AN24NC.41AN23Spare_out42AN22immobilizer43AN21Engine_Temp44AN20Air_Temp45AN19Fuel_level46AN18Oil_pressure47AN17Barometric Air pressure48AN16V_battery49AN15sensors_supply_150AN14sensors_supply_251VANGGD0GND52VAREF03.3V53VSSMGND54VDDM3.3V55AN13Pedal_position_156AN12Pedal_position_157AN11Pedal_position_258AN10Pedal_position_259AN9TPS_160AN8TPS_161AN6TPS_262AN5MAP(level shift)63AN4MAP64AN3lambda_sensor_265AN2lambda_sensor_166AN1lambda_heat_current67AN0IGN_current68VDD1.5V69VDDP3.3V70VSSGND71AD0EMUX0/P1.12NC.72AD0EMUX1/P1.13NC.73AD0EMUX2/P1.14NC.74GPTA32/P2.0speed display output75GPTA33/P2.1speed display output overcurrent76GPTA34/P2.2OBD LED output77GPTA35/P2.3OBD LED output current78GPTA36/P2.4stepper motor driver fault pin79GPTA37/P2.5stepper motor driver fault pin80GPTA38/P2.6stepper motor A phase Enable pin81GPTA39/P2.7stepper motor B phase Enable pin82VSSGND83VDDP3.3V84VDD1.5V85VSSGND86GPTA28/P4.0lambda heat 187GPTA29/P4.1lambda heat 288GPTA30/P4.2TLE8104 fault pin input89NC.NC.90GPTA31/P4.3NC.91GPTA16/P1.0ignition 192GPTA17/P1.1code test crank93GPTA18/P1.2code test94GPTA48/P1.8stepper motor A phase (+)95GPTA49/P1.9stepper motor A phase (-)96GPTA50/P1.10stepper motor B phase (+)97GPTA51/P1.11stepper motor B phase (-)98GPTA19/P1.3ignition 299VDD1.5V100VDDP3.3V101VSSGND102XTAL1XTAL1103XTAL2XTAL2104VSSOSCGND105VDDOSC1.5V106VDDOSC33.3V107GPTA20/P1.4ignition 3108GPTA21/P1.5ignition 4109GPTA22/P1.6ignition current detecting110GPTA23/P1.7ignition over current detecting111TDITDI112TMSTMS113TDOTDO114/TRST/TRST115TCKTCK116/BRKOUT/BRKOUT117/BRKIN/BRKIN118/TESTMODE/TESTMODE119BYPASSBYPASS120/PORST/PORST121NMINMI122/HDRST/HDRST123VDD1.5V124VDDP3.3V125VSSGND126SLSO0/P3.5SLSO0127SLSO1/P3.6SLSO1128TXD1A/P3.8KWP TXD129SCLK0/P3.2SCLK0130MRST0/P3.3MRST0131SLSO2/P3.7SLSO2132MTSR0/P3.4MTSR0133TXDCAN1/P3.15NC.134RXDCAN1/P3.14NC.135TXD0A/P3.1SCI TXD0136RXD0A/P3.0SCI RXD0137REQ0/P3.10NC.138RXD1A/P3.9KWP RXD139VDDP3.3V140VSSGND141VDDFL33.3V142TXDCAN0/P3.13CAN_TXD1143RXDCAN0/P3.12CAN_RXD1144REQ1/P3.11NC.145GPTA0/P0.0power supply reset output 1 146GPTA1/P0.1power supply control147GPTA2/P0.2detect IGN state148GPTA3/P0.3code test cam149GPTA8/P0.8injector 1150GPTA9/P0.9injector 2151GPTA10/P0.10crank signal 152GPTA11/P0.11injector 3153VDD1.5V154VDDP3.3V155VSSGND156FCLN0FCLN0157FCLP0AFCLP0A158SON0SON0159SOP0ASOP0A160ENO1/P2.9NC.161MRST1A/P2.10MRST1162SCLK1A/P2.11SCLK1163MTSR1A/P2.12MTSR1164EN00/P2.8ENO0165SDI0/P2.13SDI0166GPTA4/P0.4ETC power device Enable167GPTA5/P0.5ETC power device error detecting168GPTA12/P0.12injector 4169GPTA13/P0.13injector power device Enable170VDD1.5V171VDDP3.3V172VSSGND173GPTA6/P0.6cam siganl input174GPTA7/P0.7Power device reset output175GPTA14/P0.14ETC contol 1176GPTA15/P0.15ETC contol 24.2 Power supply moduleIn this design, there is only one chip (TLE7368- Next generation micro controller supply) for power supply. The TLE7368 has features as follows:l High efficient next generation micro controller power supply system:l Wide battery input voltage range 4.5V up to 45Vl Operating temperature range -40C Tj 150Cl Pre-regulator for low all over power loss:Integrated current mode Buck converter 5.5V/2.5Al Post-regulators, e.g. for system and controller I/O suppply:- LDO1: 5V 2%, 800mA current limit- LDO2: 3.3V 2% or 2.6V 2% (selectable output), 700mA current limitl Integrated linear regulator control circuit to supply controller cores:- LDO3 control for an external NPN power stage: 1.5V 2%l Post-regulators for off board supply:- 2 Tracking regulators following the main 5V, 120mA and 50mAl Stand-by regulator with lowest current consumption:- Linear voltage regulator as stand-by supply for e.g. memory circuits- Hardware selectable output voltages as 1.0V or 2.6V, 30mA- Independent battery input, separated from Buck regulator inputl Hardware controlled on/off logicl Undervoltage detection:- Undervoltage reset circuits with adjustable reset delay time at power up- Undervoltage monitoring circuit on stand-by supplyl Window watchdog circuitl Overcurrent protection on all regulatorsl Power sequencing on controller suppliesl Overtemperature shutdownThe block diagram of TLE7368 is shown in fig.3.Fig.3. block diagram of TLE7368The purpose of the power supply (TLE7368- Next generation micro controller supply) is to provide 3.3V and 1.5V to the microcontroller, 3.3V and 5V to the other peripheral circuits in the ECU and two 5V voltage trackers for external sensors like the TPS. Therefore the voltage is capturing by micro ADC, this ensures that that the ADC readings of the micro are not affected by variations in the 5V supply. In addition shorts to ground or battery of the 5V sensor supply will not affect the internal 5V and the microcontroller will continue to control injectors, spark and fuel pump.One feature in this design is TLE7368 have Undervoltage detection. When the voltages of power supply module, the reset signal will be outputted that will reset micro or trig micro extern interrupt. This interruption will inform the micro that power su