Functional Safety of the Electronics Systems at the High Level - - PowerPoint PPT Presentation

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Functional Safety of the Electronics Systems at the High Level - - PowerPoint PPT Presentation

21st International Forum on Advanced Microsystems for Automotive Applications Berlin, 25-26 September 2017 Smart Features Integrated for Prognostics Health Management Assure the Functional Safety of the Electronics Systems at the High Level


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SLIDE 1

Micro Materials Center

Head: Prof. Dr. Sven Rzepka

Smart Features Integrated for Prognostics Health Management Assure the

Functional Safety

  • f the Electronics Systems at the High Level

Required in Fully Automated Vehicles

Sven Rzepka1 and Przemyslaw J. Gromala2

1Fraunhofer ENAS, Chemnitz, Germany 2Robert Bosch GmbH, Reutlingen, Germany

sven.rzepka@enas.fraunhofer.de; +49-371-4500-1421

21st International Forum on Advanced Microsystems for Automotive Applications

Berlin, 25-26 September 2017

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SLIDE 2

Micro Materials Center

Head: Prof. Dr. Sven Rzepka

Intro Introdu ductio ction

  • Automated Cars:

 Functional safety requirement exceeds today's automotive spec

  • SoA approach: System-level redundancy

Number & Complexity of ECUs  , Driver  Passenger  Will soon be unaffordable

  • New approach in AE: Active Prognostic Health Management (PHM)
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SLIDE 3

Micro Materials Center

Head: Prof. Dr. Sven Rzepka

Prognostics and Health Manage- ment (PHM)

  • Developing the required infras-

tructure, sensors, electronic HW

  • Studying and characterizing the

Failure Modes and Mechanisms by thorough Effect Analyses for PoF & data driven approaches

  • Providing appropriate solutions

to the data acquisition, manage- ment, and secure data transfer

  • Performing data fusion for reach-

ing at an integrated single health assessment, diagnostics, and prognosis score per application

  • Establishing highly efficient yet

precise metamodeling and mod- el order reduction schemes that can be executed in each of the individual cars locally assisted by self-learning capabilities provid- ed by cloud service

Prognostic Health Management

Experimental & Design Area Infrastructure, Sensors, Hardware

Prognostic Health Management

Experimental & Design Area Infrastructure, Sensors, Hardware FMMEA / Physics of Failure, Data Driven Approach

Prognostic Health Management

Engineering Focus Experimental & Design Area Infrastructure, Sensors, Hardware FMMEA / Physics of Failure, Data Driven Approach Data Acquisition, Management & Transfer

Prognostic Health Management

Engineering Focus Experimental & Design Area Algorithm Framework Infrastructure, Sensors, Hardware FMMEA / Physics of Failure, Data Driven Approach Data Acquisition, Management & Transfer Health Assessment, Diagnostics, Prognostics

Prognostic Health Management

Engineering Focus Experimental & Design Area Algorithm Framework Infrastructure, Sensors, Hardware FMMEA / Physics of Failure, Data Driven Approach Data Acquisition, Management & Transfer Health Assessment, Diagnostics, Prognostics

Prognostic Health Management

Meta Models, Model Order Reduction Engineering Focus Experimental & Design Area Algorithm Framework Infrastructure, Sensors, Hardware FMMEA / Physics of Failure, Data Driven Approach Data Acquisition, Management & Transfer Health Assessment, Diagnostics, Prognostics

Prognostic Health Management

Meta Models, Model Order Reduction

Acceleration Models Variation- induced fai- lure risks Critical Parameters in Extreme Environments Data Readout & Processing Infrastructure Integration

  • f new Sensors

Collectors (Sensors, Canaries, …) Consolidation of Health Assessment Data (Sources) Data Exploration and Hypothesis Generation PoF Model Generation and Validation Demonstration

  • f AE System

Integration Standardized Safe and Secure Data Exchange Model Improvement for Signals Real T ime Prediction Capabilities

Dedicated stops and three methodology research phases  Strategy: PHM integrated into ECS

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SLIDE 4

Micro Materials Center

Head: Prof. Dr. Sven Rzepka

Development of a Comprehensive Scheme of Multi-level

Prognostics and and Health Management (PHM)

PHM features: Self-Detecting

  • 1. Circuit-level: Event detectors added

Wafer-level: Sensors added to the ICs IC component-level: Extra solder joints

  • 2. Passive component-level: Canaries
  • 3. Board component-level: Local warpage

PHM objects: Self-Monitoring

  • 4. Board-level: Smart sensors provide data

Local PHM Unit: Self-Diagnosing

  • 5. Module-level: One SiP collects, prepro-

cesses & communicates the PHM data

Central PHM ECU: Self-Deciding

  • 6. Vehicle-level: PHM ECU inside the central

computer determines RUL based on meta- models and compiles the 'health score'

PHM Cloud & Swarm: Self-Learning

  • 7. Global Level: Database & HPC support
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SLIDE 5

Micro Materials Center

Head: Prof. Dr. Sven Rzepka

Integ Integrated rated Smart Smart Fe Featu atures res for Prognostics and Health Management

PHM Feature @ wafer-level: Sensors added to the ICs

[-110] direction

SoA: 50 x 50 µm² 5 x 5 µm² CNT based stress sensors

in cooperation with TU Chemnitz, ZfM

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SLIDE 6

Micro Materials Center

Head: Prof. Dr. Sven Rzepka

Integ Integrated rated Smart Featu Smart Features res for Prognostics and Health Management

PHM Feature @ IC component-level: Dedicated / Extra solder joints

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SLIDE 7

Micro Materials Center

Head: Prof. Dr. Sven Rzepka

N63

Integ Integrated rated Smart Featu Smart Features res for Prognostics and Health Management

PHM Feature @ Passive component-level: Canaries

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SLIDE 8

Micro Materials Center

Head: Prof. Dr. Sven Rzepka

Integ Integrated rated Smart Featu Smart Features res for Prognostics and Health Management

PHM Feature @ Board component-level: Local warpage

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SLIDE 9

Micro Materials Center

Head: Prof. Dr. Sven Rzepka

Integ Integrated rated Smart Featu Smart Features res for Prognostics and Health Management

PHM Feature @ Board component-level: Local warpage

3 2

2 – Stress Sensor 3 – Temperature Sensor

Healthy Fault

Cycle 81 Stress evolution underneath the device

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SLIDE 10

Micro Materials Center

Head: Prof. Dr. Sven Rzepka

Development of a Comprehensive Scheme of Multi-level

Prognostics and Health Management (PHM)

Further challenges requiring advances in Reliability Methodology: Assessment of the Field Data: Handle the Data Flood / Correlate to Tests Identify Key Failure Indicators (KFI) for Triggering Maintenance / Repair Determine Remaining Useful Life (RUL) by Exp. & Sim.  RUL-Models Metamodeling: Determine most effective Input & Output Parameters Health Score: Fuse all PHM Data into a Single Quantity  Maintenance Self-Learning: Load case & damage parameter systematics  Databases Self-Learning: Automated Load Case Assessments by Simulation  HPC

Applicable PHM strategies - Ready for implementation by RIA