The thesis is focused on determining the methodology of engine diagnostics for vehicles with common rail direct fuel injection. The first section describes the communication between the diagnostic tools and control units, and the common rail system for diesel engines. The next section specifies the procedure for the acquisition, processing and analysis of data using selective diagnostic tools along with software in a numerical computing environment. Subsequently, from the results, the equivalent electronic control of the fuel injection quantity is established for the purpose of research, vehicle servicing. The results may also allow for additional observations to be made.

The goal of the master´s thesis is to design testing unit for small batch production. The background research part introduces testing principles, we are also discussed different ways of realization of testing connectors and choice of control unit. The work also describes the design of the hardware wiring and mechanical design. The result of this thesis is a device implemented according to the proposal described in the work. No significant fault was found during operation of testing unit, which verified its reliability and full functionality. The work also includes a description of the software implementation in Python.

I detta examensarbete utreddes huruvida elektriska tester av styrenheter för tunga fordon kan automatiseras på befintliga testmiljöer. Arbetet utfördes på uppdrag av Scania CV AB för arbetsgruppen Electronic Hardware som utför tester vid utveckling och verifiering av krav på styrenheter. Genom en automatiserad testprocess kan testarbetet effektiviseras och kvaliteten höjas. Testarbetet sker på testriggar som innehåller fullskalig hårdvara från lastbilar för att kunna emulera styrenhetens autentiska arbetsmiljö. För att komma fram till ett testsystem som kunde leva upp till de krav och behov som formulerats inom kravprocessen i arbetet användes utvecklingsmodeller. Utvärderingsmatriser användes för att välja den mjuk- och hårdvara som skulle vara mest lämplig för det automatiserade testsystemet utifrån kraven. Resultatet visade att testsystemet skulle bestå av en testprogramvara som körs på en vanlig persondator och ett inbyggt system med elektroniska komponenter för att kunna utföra de elektriska testerna. För att demonstrera testsystemets möjligheter i ett helhetstest konstruerades en prototyp som har funktionalitet att utföra ett testfall som kan dra stor nytta av att automatiseras, nämligen att testa omslagsnivåer för en digital ingång. Prototypen baserades på ett mikrokontrollerkort från Arduino och ett kretskort konstruerades till detta för att kunna utföra elektriska tester med högre spänningsnivåer som krävs för styrenheter på Scaniafordon. För att utforma testfall och hantera testprocessen valdes LabVIEW, en programvara där tester designas med ett grafiskt programmeringsspråk. Testresultaten för prototyptestsystemet visade att verifieringen av kraven för omslagsnivåer förenklas radikalt vid ett automatiserat förfarande, eftersom testtiden kunde minskas drastiskt, i synnerhet vid ett repetitivt förfarande. / This thesis work intends to study the possibilities to automate electrical testing of electronic control units in an existing test environment. The work was executed on behalf of Scania CV AB for the department Electronic Hardware, who run tests in development and verification of requirements for electronic control units. By using an automated testing system, the testing process could be made more effective and raise the quality. The testing work is done on test rigs which are equipped with full-scale hardware from real trucks to emulate the working environment the electronic control unit operates into. Development models were used to be able to create a testing system which could meet the requirements that were defined during the requirement engineering process. Evaluation matrices were used to choose the soft- and hardware that could be considered the most appropriate for the automated testing system according to the requirements. The result shown that the testing system should consist of a testing software that runs on an ordinary computer and an embedded system equipped with electronic components to enable the testing system for electrical tests. To demonstrate the possibilities of the whole testing system a prototype was manufactured which was designed to execute a test case that could greatly benefit from the advantages that comes with automation. It was a test case set out to measure voltage levels when switching in a digital input. The prototype was based on a microcontroller card from Arduino and was joined by a printed circuit board to be able to run electrical tests with the higher voltage levels that were demanded by electronic control units. To design test cases and manage the test process, LabVIEW was chosen, a software in which tests are designed in a graphical programming language. Test results for the prototype test system showed that verification of the requirements for voltage levels when switching was radically simplified by an automated procedure, as the test time could be drastically reduced, particularly in a repetitive procedure.

As the automotive industry becomes increasingly reliant on digital systems it is of utmost importance that these systems are secure. Secure systems are of interest both for the general public as well as manufactures. This Master’s thesis evaluates potential cybersecurity solutions for a proposed damper system prototype developed by Öhlins Racing AB. A systematic literature study was performed to identify known vulnerabilities of similar systems as well as potential cybersecurity solutions. A threat model was constructed using vehicleLang, the Meta Attack Language, and securiCAD. The model was created utilizing preexisting assets from vehicleLang and a newly implemented Bluetooth asset. The result from the systematic literature study was used to validate preexisting attack steps and also to create the Bluetooth asset. To validate the model, experts in the field of automotive security and/or threat modeling were asked to assess the model. Using Cochran’s Equation, a target of eight expert evaluations were decided. Unfortunately, only seven evaluations were obtained, equivalent to an increase in the error margin from 25% to 26.6%. However, of the seven expert evaluations obtained none indicated the existence of critical flaws within the model. The model was therefore considered a good reflection of the damper system and its security aspects. Critical defenses included the utilization of cryptography, mutual authentication, and on-the-fly decryption. These defenses were shown to prevent unauthorized modifications of firmware and protect Öhlins intellectual property in form of source code. While it was not possible to defend against all attacks the identified defenses would increase the safety and security of the system, benefiting not only Öhlins but also overall road users. / Allt eftersom fordonsindustrins beroende av digitala system ökar är det av yttersta vikt att dessa system är säkra. Säkra system är av intresse för både allmänheten likväl som för systemtillverkarna. Denna masteruppsats evaluerar potentiella cybersäkerhetslösningar för en föreslagen stötdämparprototyp utvecklad av Öhlins Racing AB. En systematisk litteraturöversikt skapades med syfte att identifiera kända sårbarheter av liknande system och potentiella cybersäkerhetslösningar. En hotmodell skapades med hjälp av vehicleLang, the Meta Attack Language, och securiCAD. Hotmodellen skapades med existerande komponenter från vehicleLang och en nyskapad Bluetooth komponent. Resultaten från den systematiska litteraturöversikten användes för att validera existerande komponenter från vehicleLang och för implementationen av Bluetooth komponenten. För att evaluera modellen bads experter inom fordonssäkerhet och/eller hotmodellering utvärdera modellen. Genom Cochran’s ekvation beslutades att åtta expert utvärderingar skull införskaffas. Tyvärr erhölls enbart sju utvärderingar, vilket motsvarar en ökning av felmarginalen från 25% till 25.6%. Av de sju experter som utvärderade modellen identifierades dock inga kritiska brister. Kritiska säkerhetslösningar inkluderade användandet av: kryptografi, ömsesidig autentisering, och on-the-fly decryption. Dessa försvar anses kunna skydda mot obehörig modifiering av programvara, samt skydda Öhlins intellektuella egendom i form av källkod. Trots att det inte var möjligt att förhindra alla attacker skulle de identifierade försvaren öka systemets säkerhet, vilket är fördelaktigt inte bara för Öhlins utan även trafikanter i allmänhet.

Nas últimas décadas, a indústria automobilística mundial vem investindo no desenvolvimento tecnológico dos motores, com o objetivo de alcançar melhor eficiência energética e atender às legislações que limitam a quantidade de resíduos tóxicos nos gases de exaustão e menor consumo de combustível. Isso resultou na implantação dos sistemas de gerenciamento eletrônico do motor, que possibilitam funcionalidades para se controlar diversas variáveis do motor, aumentando consideravelmente o rendimento do motor. Este trabalho tem como objetivos explorar a dinâmica de um motor de combustão interna ciclo Otto, os sinais elétricos associados, e os componentes de seu gerenciamento eletrônico. A partir dessas informações, o trabalho apresenta o processo de analise dos sinais elétricos e as estratégias de controle utilizadas em um sistema de gerenciamento real. Assim, são desenvolvidos o hardware e o firmware de uma unidade microcontroladora para gerenciamento eletrônico do motor. O hardware foi elaborado com uma concepção centralizada, ou seja, foi usado apenas um microcontrolador de 32-bit para gerenciar todas as funções. O firmware de controle foi desenvolvido de forma modular baseado em modelos de malha fechada. O modelo matemático do motor foi identificado utilizando técnicas de controle em um veículo real, e a avalidação do modelo foi obtida através de testes em um dinamômetro inercial. / In the last few decades, the world automotive industry has invested in the technological development of the engines, aiming to get better energetic efficiency and comply with legislations that limit the amount of toxic exhaustion gases. This resulted in electronic management systems for engines, which allowed flexibility to control several engine-related variables, considerably increasing the engine efficiency. This work aims to explore the Otto cycle combustion engine dynamics, its electronic signals, and the elements of its electronic management. Based on that information, this work presents the analysis process of the electronic signals, and the control strategies used in a real management system. Then, the hardware and firmware of a microcontroller unity are developed for the electronic management of the engine. The hardware was elaborated with a centralized concept, i.e., only one 32-bit microcontroller was used to control all functions. The control firmware was developed in a modular scheme, based on the closed loop models. The engine mathematical model was identified using control techniques in a real engine. The results were obtained by tests in an inertial dynamometer.

Nas últimas décadas, a indústria automobilística mundial vem investindo no desenvolvimento tecnológico dos motores, com o objetivo de alcançar melhor eficiência energética e atender às legislações que limitam a quantidade de resíduos tóxicos nos gases de exaustão e menor consumo de combustível. Isso resultou na implantação dos sistemas de gerenciamento eletrônico do motor, que possibilitam funcionalidades para se controlar diversas variáveis do motor, aumentando consideravelmente o rendimento do motor. Este trabalho tem como objetivos explorar a dinâmica de um motor de combustão interna ciclo Otto, os sinais elétricos associados, e os componentes de seu gerenciamento eletrônico. A partir dessas informações, o trabalho apresenta o processo de analise dos sinais elétricos e as estratégias de controle utilizadas em um sistema de gerenciamento real. Assim, são desenvolvidos o hardware e o firmware de uma unidade microcontroladora para gerenciamento eletrônico do motor. O hardware foi elaborado com uma concepção centralizada, ou seja, foi usado apenas um microcontrolador de 32-bit para gerenciar todas as funções. O firmware de controle foi desenvolvido de forma modular baseado em modelos de malha fechada. O modelo matemático do motor foi identificado utilizando técnicas de controle em um veículo real, e a avalidação do modelo foi obtida através de testes em um dinamômetro inercial. / In the last few decades, the world automotive industry has invested in the technological development of the engines, aiming to get better energetic efficiency and comply with legislations that limit the amount of toxic exhaustion gases. This resulted in electronic management systems for engines, which allowed flexibility to control several engine-related variables, considerably increasing the engine efficiency. This work aims to explore the Otto cycle combustion engine dynamics, its electronic signals, and the elements of its electronic management. Based on that information, this work presents the analysis process of the electronic signals, and the control strategies used in a real management system. Then, the hardware and firmware of a microcontroller unity are developed for the electronic management of the engine. The hardware was elaborated with a centralized concept, i.e., only one 32-bit microcontroller was used to control all functions. The control firmware was developed in a modular scheme, based on the closed loop models. The engine mathematical model was identified using control techniques in a real engine. The results were obtained by tests in an inertial dynamometer.

The concept of translating source code into other target programming languages is extensively used in a wide area of applications. Danfoss Power Solutions AB, a company located in Älmhult, strives to streamline their way of software development for microcontrollers by implementing this idea. Their proprietary software tool PLUS+1 GUIDE is based on the CAN bus communication network, which allows electronic control units to share data represented in the XML format. Due to compatibility problems, the application in the electronic control units requires this data to be translated into the source code in the low-level C programming language. This thesis project proposes an approach for facilitating this task by implementing a source-to-source compiler that performs the translation with a reduced level of manual user involvement. A literature review was conducted in order to find the existing solutions relevant to our project task. An analysis of the provided XML input files was thereafter performed to clarify a software design suitable for the problem. By using a general XML parser, a solution was then constructed. The implementation resulted in a fully functional source-to-source compiler, producing the generated C code within a time range of 73–85 milliseconds for the input test files of typical size. The feedback received from the domain experts at Danfoss confirms the usability of the proposed solution.

Nowadays almost all motorized vehicles use electronic control units (ECUs) to control parts of a vehicle’s function. A good way to understand a vehicle’s behaviour is to analyse logging data containing ECU internal variables. Data must then be transferred from the ECU to a computer in order to study such data. Today, Keyword Protocol (KWP) requests are used to read data from the ECUs at Scania. The method is not suitable if many signals should be logged with a higher transfer rate than the one used today. In this thesis, communication protocols, that allow an ECU to communicate with a computer, are studied. The purpose of this master’s thesis is to examine how the transfer rate of variables from Scania’s ECUs to a computer can become faster compared to the method used today in order to get a more frequent logging of the variables. The method that was chosen was implemented, evaluated and also compared to the method used today. The busload, total CPU load and CPU load for the frequency used during the experiments, 100 Hz, was also examined and evaluated. The experiments performed show that the method chosen, data acquisition (DAQ) with CAN Calibration Protocol (CCP), increased the transfer rate of the internal ECU variables significantly compared to the method using KWP requests. The results also show that the number of signals have a major impact on the busload for DAQ. The busload is the parameter that limits the number of signals that can be logged. The total CPU load and the CPU load for 100 Hz are not affected significantly compared to when no transmissions are performed. Even though the busload can become high if many variables are used in DAQ, DAQ with CCP is preferable over KWP requests. This is due to the great increase in transfer rate of the ECU internal variables and thus a great increase in the logging frequency. / Nuförtiden används styrenheter (ECUer) för att styra delar av ett fordons funktion i så gott som alla motoriserade fordon. Ett bra sätt att förstå ett fordons beteende är att analysera loggningsdata som innehåller interna styrenhetsvariabler. Data måste då överföras från styrenheten till en dator för att data ska kunna studeras. Idag används Keyword Protocol-förfrågningar (KWP-förfrågningar) för att läsa data från Scanias styrenheter. Metoden är inte lämplig om man vill logga många variabler med en högre överföringshastighet än den som används idag. I detta examensarbete studeras kommunikationsprotokoll som tillåter en styrenhet att kommunicera med en dator. Examensarbetets syfte är undersöka hur överföringshastigheten av variablerna, från Scanias styrenheter till en dator, kan ökas jämfört med den metod som används idag för att få en mer frekvent loggning av variablerna. Metoden som valdes implementerades, utvärderades och jämfördes med metoden som används idag. Busslasten, totala CPU-lasten och CPU-lasten för den frekvens som användes under experimenten 100 Hz har också undersökts och evaluerats. De utförda experimenten visar att den valda metoden, data acquisition (DAQ) med CAN Calibration Protocol (CCP), ökade överföringshastigheten av de interna styrenhetsvariablerna betydligt jämfört med metoden KWP-förfrågningar. Experimenten visar också att antalet signaler har stor inverkan på busslasten för DAQ. Busslasten är den parameter som begränsar antalet signaler som kan loggas. Den totala CPU-lasten och CPU-lasten för 100 Hz påverkas inte betydligt jämfört med när inga överföringar görs. DAQ med CCP är att föredra framför KWP-förfrågningar även om busslasten blir hög för DAQ då den stora ökningen i överföringshastighet av de interna styrenhetsvariablerna medför en mer frekvent loggning av variablerna.

Automotive industry has moved from manufacturing automobiles using mechanical units to using Electronic Control Units (ECUs). One of the integral parts of ECUs are the microcontrollers. Selecting the right microcontroller unit for the ECU in automotive industry, involves high time and cost factors, as several criteria need to be examined for each microcontroller in the market. There is a need for a methodology for selection of the microcontroller based on the given requirements, with the aid of some tools, to reduce the time and cost factors. This thesis involves determining criteria for automotive microcontrollers and selection of the microcontroller by following a systematic process. A part of the systematic process involves filtering or ranking microcontrollers according to the requirements and plotting microcontrollers for the required criteria along with pareto-front analysis of rank versus cost. Ranking of microcontrollers is done using Goal Programming and Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) methods. The result from the thesis shows various criteria for the microcontroller in an ECU and the methodology to be followed for microcontroller selection using case study of Exterior Lighting System. The results of Goal Programming and TOPSIS methods show that they could provide good aid in selection by ranking the microcontrollers along with pareto-front analysis. Finally, a selection methodology guideline has been formulated to aid the selection process with the help of the methods. / Fordonsindustrin har gått från att tillverka bilar med mekaniska styrsystem till att använda elektroniska styrenheter (ECU:er). En central del i styrenheterna är mikrokontrollers. Att välja rätt mikrokontroller för en ECU i fordonsindustrin är tidskrävande och kostnadsintensivt eftersom många faktorer behöver tas i beaktning och undersökas för varje mikrokontroller på marknaden. Det finns ett behov för en metod att välja mikrokontroller utifrån en given kravställning, med hjälp av olika verktyg, för att minska utvecklingstid och kostnad. Detta examensarbete handlar om att fastställa relevanta kriterier för fordonsrelaterade applikationer som använder mikrokontrollers samt urval av mikrokontrollers genom att följa en systematisk metod. En del av den metoden är filtrering och rangordning av alternativen utifrån kravställningen och visualisering hur jämförelsealternativen uppfyller kravställningen jämte Pareto-front analys mellan rangordning och kostnad. Rangordning görs med hjälp av metoderna Målprogrammering och Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS). Resultatet av examensarbetet visar olika kriterier för en mikrokontroller i en ECU och metoderna att använda sig av för val av mikrokontroller i studieexemplet ett belysningsstyrningssystem. Resultaten av metoderna målprogrammering och TOPSIS visar att de kan vara till god hjälp i valet genom rangordning av mikrokontrollers med tillägg av Pareto-front-analys. Slutligen har en guide för urvalsmetod skapats för att hjälpa urvalsprocessen med hjälp av metoderna.

Práce se zabývá návrhem automobilové elektronické řídicí jednotky (ECU) s funkcí partial networking definovanou normou ISO 11898-6. Cílem je navrhnout a vytvořit demonstrační ECU s použitím system basis chip NCV7471. Protože NCV7471 obsahuje standardní CAN transceiver, funkce partial networking je realizována pouze softwarem řídicí jednotky. Práce zvažuje možné způsoby realizace jak HW, tak SW části, tak aby byla zajištěna nízká spotřeba ECU v různých operačních módech, a snaží se sledovat současné trendy v automobilovém průmyslu.