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Electronics
Electronics
Automotive Technology:
Greener Vehicles, Changing Skills
MAY 2011
Automotive Technology:
Greener Vehicles, Changing Skills
ELECTRONICS, SOFTWARE & CONTROLS REPORT
Research conducted by the
Center for Automotive Research
This project was supported by a grant from the
U.S. Employment and Training Administration
This workforce solution was funded by a grant awarded by the U.S. Department of Labors Employment and Training Administration. The
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This report, published May 2011, is part of the larger Driving Change
Project funded by the U.S. Employment and Training Administration.
For more information, visit www.drivingworkforcechange.org.
i
Table of Contents
TABLE OF CONTENTS ........................................................................................ I
1. INTRODUCTION ........................................................................................ 1
1.1 Methodology ........................................................................................................................................................................ 2
2. VEHICLE ELECTRONIC SYSTEMS: MARKET OVERVIEW .................................... 3
3. KEY VEHICLE ELECTRONIC SYSTEM DESCRIPTIONS ........................................ 7
3.1 Powertrain and Transmission Controls ........................................................................................................................ 7
3.2 Vehicle Communications .................................................................................................................................................. 8
3.3 Vehicle Safety Systems ..................................................................................................................................................... 10
3.4 Mobility Enhancement ..................................................................................................................................................... 11
3.5 Infotainment Systems ....................................................................................................................................................... 11
3.6 Risks to Development of Mobility and Infotainment Applications ....................................................................... 12
3.6.1 Distracted Driving ............................................................................................................................................................................................... 12
3.6.2 Privacy Concerns ................................................................................................................................................................................................ 14
3.6.3 Cyber Security Concerns .................................................................................................................................................................................. 15
4. ELECTRONIC COMPONENTS OVERVIEW ...................................................... 16
4.1 Microcontrollers ............................................................................................................................................................... 16
4.2 Automotive Sensors ........................................................................................................................................................ 16
4.3 Actuators ............................................................................................................................................................................ 18
4.4 Automotive Data Buses .................................................................................................................................................. 19
4.4.1 Types of Automotive Buses .............................................................................................................................................................................. 19
5. FUTURE ACTIVITY ................................................................................... 20
5.1 Vehicle Electronic Trends .............................................................................................................................................. 20
5.1.1 Illustrative Case Study: Keyless Entry Systems .............................................................................................................................................. 21
5.2 Electronic and Technological Applications ................................................................................................................. 22
6. IMPACT ON WORK FORCE SKILLS .............................................................. 24
6.1 Skills Needed ..................................................................................................................................................................... 24
6.2 Number of Workers and Locations ............................................................................................................................ 26
7. CONCLUSIONS ........................................................................................ 30
Index of Figures
Figure 1: Total Number of U.S. Motor Vehicle Electronics Jobs Has Fallen in Recent Years, While the Percent of Motor Vehicle
Jobs That Are in Electronics Has Risen .................................................................................................................................................... 4
Figure 2: Types of Automotive Sensors .................................................................................................................................................................... 18
Figure 3: Timeline for Selected and Notable Projected Milestones in Vehicle Electronics ........................................................................ 21
ii
Figure 4: Passive Keyless Entry Systems Market Forecast for North America .............................................................................................. 22
Figure 5: Motor Vehicle Electronics Employment in Ohio .................................................................................................................................. 27
Figure 6: Motor Vehicle Electronics Employment in Indiana ............................................................................................................................... 28
Figure 7: Motor Vehicle Employment in Michigan .................................................................................................................................................. 28
Index of Tables
Table 1: Changes in PCM Hardware and Software ................................................................................................................................................. 8
Table 2: Motor Vehicle Electronics and Information Systems Skill Assessment ........................................................................................... 25
1
1. Introduction
Vehicle electronics and communications represent a significant growth area in the motor vehicle
sector. Vehicles house an increasingly complex array of electronics; electronic couplings have,
over time, replaced mechanical couplings across a broad array of vehicle systems and
subsystems. Today, electronics (in the form of sensors), actuators, micro-processors,
instrumentation panels, controllers and displays appear in nearly all major vehicle systems,
including:
Engine controllers and sensors
Safety systems
Chassis control
Measurement and diagnostic modules
Entertainment systems
Navigation systems
Communication systems
In the last 20 to 30 years, electronics have introduced functionality not possible in a purely
mechanical framework. Perhaps most obviously, this new functionality appears in safety
systems (electronic stability control, tire-pressure monitoring, hands-free calling, etc.),
navigation systems and entertainment systems (Bluetooth
,
which integrated passive (hazard-detection technology) and active (seatbelt tensioners and
automatically adjusting seats and windows) safety features. The Mercedes system monitors
vehicle behavior and sends warning signals to the driver if conditions become hazardous. When
situations become critical, active safety systems like electronic stability control are deployed. If
a crash is likely, other safety systems are engaged: front and rear seats move to position
occupants upright, belts are tensioned, knee bolsters are extended and windows are
automatically closed.
42
Automotive suppliers are now marketing similar systems. Continental
has devised a system called Active Passive Integration Approach and Denso has created the
Pre-Collision System.
43
38
US Department of Transportation. (2010). IntelliDrive
SM
: Safer. Smarter. Greener. Accessed May 7, 2010.
<http://www.intellidriveusa.org/about/overview.php>.
39
Fischer, Kirsten. (2006). Auto Electronics Market to Exceed US$50 Billion by 2010. Reed Electronics Research. September 19, 2006.
40
Prosser, S. J. (2007). Automotive Sensors: Past, Present, and Future. Journal of Physics: Conference Series 76 012001
41
Ealey, Lance and Miller, Glenn. (1999). Telematics: Where the radio meets the road. The McKinsey Quarterly. Spring 1999 i2 p6(1).
42
SRS. (2009). Vehicle and Product Safety: Crash Prevention. Safety Research & Strategies, Inc. 2009.
<http://www.safetyresearch.net/safety-issues/crash-prevention/>.
43
Ibid.
11
Connected vehicle applications can further promote safety by enabling vehicles to have 360-
degree awareness, informing drivers of hazards and situations they cannot see and reducing
crashes through advisories and warnings. These warnings might include advisories for entering
a school zone, approaching a sharp ramp curve, nearing an area with slippery roads or other
hazardous conditions. This warning system also allows users to take into account the timing of
traffic signals to know whether it is safe to cross an intersection or whether they should stop at
the light. Drivers could also be advised of the presence of bicycles and pedestrians equipped
with vehicle communication devices, enhancing safety for all users.
44
3.4 Mobility Enhancement
The information created by vehicle communication applications could be used to improve
mobility. Using information gathered through the communications network, transportation
managers can monitor and manage transportation system performance (adjusting traffic
signals, transit operations, or dispatching maintenance/emergency personnel). Emergency
vehicles will be able to send signals to traffic lights at intersections en route to calls, stopping
cross traffic and ensuring a clear path to the emergency site. Commercial and municipal fleet
operators will be able to use vehicle communications to manage resources more efficiently:
reducing travel times, lowering costs and improving the environmental impact. Similarly,
individuals in personal vehicles will be able to use real-time information about traffic congestion
and other conditions to make more informed route decisions. By optimizing travel routes, users
can save time, fuel and money. By using personal communication devices, travelers can
optimize their transportation strategies, avoiding congestion by taking alternate routes or using
alternate modes of transportation (e.g., public transit).
45
3.5 Infotainment Systems
Infotainment systems are predominantly audio and video components with versatile displays
that may be used for controlling an array of systems from audio to HVAC and navigation to
wireless Internet. The current availability of many infotainment systems products is relatively
limited to high-end vehicles and the aftermarket.
46
Increasingly, vehicle manufacturers are
attempting to include vehicle solutions that can readily integrate consumer electronics such as
the use of media-oriented systems transport (MOST) and Firewire architectures and the
inclusion of USB ports and Bluetooth
44
US Department of Transportation. (2010). IntelliDrive: Safer. Smarter. Greener. Accessed May 7, 2010.
<http://www.intellidriveusa.org/about/overview.php>.
connectivity. It is likely that by making these plug and
play architectures more common in new vehicles, there will be fewer barriers to producing
45
US Department of Transportation. (2010). IntelliDrive: Safer. Smarter. Greener. Accessed May 7, 2010.
<http://www.intellidriveusa.org/about/overview.php>.
46
IHS Global Insight. (2009). Resistance Is Futile Electronics Are on the Rise: Electronic Control Units and Communication Protocols. IHS
Global Insight, Inc. April 2009.
12
infotainment systems for vehiclesincreasing competition among suppliers to gain and
maintain market share.
47
The interfaces included in dashboards are shifting from electromechanical displays to LCDs as
the cost differential between the two options disappears.
48
As time passes, these displays are
becoming more complex, controlling dozens of functions. Careful consideration of the
ergonomics of displays and controls is becoming a more central issue, as the proper deployment
of touch screens, buttons and surfaces can be used to enhance the driver experience while
reducing distraction.
49
There are increasingly more options for entertainment systems within vehicles. Sound systems
have evolved from simple head units through CD players to include MP3 players and adaptors
for consumer music electronics. Subwoofers and amplifiers from aftermarket suppliers may be
added to improve sound quality. Infotainment options are opening: applications like integrated
navigation systems, mobile video and wireless Internet are already available in some models.
Single platform integrated systems such as UConnect and SYNC
Speech interfaces, currently available in high-end models, could play an
increasingly common role in improving safety as the legal rules governing the use of devices
requiring hand controls change.
In the next 10 years, the electronic architecture of vehicles will become more consolidated; if
electronic content continues to increase, the vehicles present electronic organization would not
be able to sustain the increase. Electronic data transmission will get faster and possibly use
more FlexRay than CAN; currently, FlexRay is much faster (higher data transmission rates)
but more expensive. Wireless data transmission is also on the horizon, most likely through
ultra-wide band (UWB).
) already allow external devices, such as smartphones and
digital music players, to interface with electronic systems built into the vehicle.
21
Figure 3: Timeline for Selected and Notable Projected Milestones in Vehicle
Electronics
2011
Electronic Stability
Control mandatedfor all
vehicles
2012
Navigation standard in
all Ford Sync-equipped
vehicles
NHTSA to decide on
mandates for lane-
departure warnings and
automatic braking
Light Duty V-to-V
Communication Decision
Increasing
personalization of
vehicles
2013 2015 2020 & Beyond
Further consolidationof
electronic architectures
On-board DSRC receivers
standard on 50% of new
vehicles
Built-in devices
to access
internet
Vehicle-infrastructure
communication devices
deployed at most
intersections
2016
New CAFE standard to
reach 34.1mpg
Heavy Duty V-to-V
Communication Decision
RITA to release
Dynamic Mobility
Apps RFP
Source: Center for Automotive Research
5.1.1 Illustrative Case Study: Keyless Entry Systems
Because the fundamental nature of vehicle electronics is not expected to change radically in the
next five to 10 years, looking at a case study of a particular technology might offer a better
picture of the growing and evolving developments in this area. Vehicle entry systems are one
good example of changing technologies within the automobile that have resulted in and will
continue to drive increased electronics content and functionality. For the better part of the last
century, vehicle entry systems were largely mechanical. In the early 1980s, the remote key hit
the market and steadily gained market share. The remote keyless entry (RKE) system uses a key
fob that has buttons used for locking and unlocking vehicle doors. The passive keyless entry
(PKE) system is another remote system which does not require the user to press buttons; rather,
this system automatically locks and unlocks vehicle doors as the key fob approaches or moves
away from the vehicle.
The RKE system is considered to be mature and is factory installed on nearly 80 percent of the
vehicles produced each year. In 1999, the PKE system was introduced and is currently factory
installed in about 10 percent of new vehicles, up from less than 5 percent just three years ago.
84
Figure 4
By 2015, PKE systems are forecast to be found factory installed in around 20 percent of new
vehicles (see ). Growth in the production of keyless entry systems is expected to speed
up between 2010 and 2012 as the North American economy recovers and the price of PKE
systems decreases. (In 2007, the price of hardware for a PKE system was over $90; by 2015, it
is expected that the price will drop to $50.)
Although the demand for PKE systems is expected to increase significantly over the next five
years, RKE will still be used in over 75 percent of new vehicles because the technology is cheaper
(less than $20 for the hardware). A small percentage (2 to 3 percent) will continue to use
mechanical keys.
85
84
Frost & Sullivan. (2009). Keyless Vehicle Entry Systems Market in North America. Frost & Sullivan. August 2009.
As entry systems become more complex, they will be able to integrate more
functionality, displaying vehicle information such as tire pressure, fuel level and live video feed;
adding security features such as fingerprint recognition; and adjusting settings to take into
85
Ibid.
22
account personal preferences (seat position, mirror adjustment and radio station presets). In
the not-too-distant future, key fobs could be replaced by mobile phones, adding even more
functionality while simplifying controls and reducing the number of devices used by consumers.
Figure 4: Passive Keyless Entry Systems Market Forecast for North America
0
5
10
15
20
25
0
5
10
15
20
2007 2008 2009 2010 2011 2012 2013 2014 2015
M
a
r
k
e
t
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Source: Frost & Sullivan. (2009)
This case study demonstrates two critical dimensions of the growing market penetration of
vehicle electronics. First, the amount of electronics in use grows by replacing functions
previously performed by mechanical systems. Second, the electronic systems themselves evolve
over time to incorporate additional functionality. Ultimately, this results in fewer distinct
componentseach with more and/or additional capabilities.
5.2 Electronic and Technological Applications
Not surprisingly, technological applications will continue to evolve as well. In the next five
years, respondents expect to see an increase in connected vehicle applications, including safety,
infotainment and mobility. Safety applications include forward collision warning, blind spot
detection and other cooperative safety technologies. Infotainment applications include those
allowing drivers and passengers to be productive in the vehicle, perhaps having the vehicle be a
kind of mobile office. People want information to be instantly and easily accessible. Along
similar lines, mobility applications on the five-year horizon include improved navigational
capabilities and location-based services. There is need for data coverage to be improved,
making navigational updates and finding restaurants or other locations near a vehicle an easier
prospect. There will also likely be limited corridor deployment of roadside communication
equipment that allows computers to monitor how quickly vehicles are moving and indicate
23
where there are backups. That info can be sent to vehicles with navigation software and alert
drivers to avoid those areas.
Distraction is an issue brought up around the mobility and infotainment aspects of vehicle
electronics technology. To combat that, one representative mentioned the use of electronic
technologies, such as speech recognition and workload management systems, to reduce the
possibility of distraction.
A final application mentioned in the five-year horizon is the ability to monitor vehicle
diagnostics. This will permit automakers to know how their vehicles are being used, as well as
allow owners to download software updates wirelessly to enhance customer convenience.
Mobile devices and computers are already updated this way; the capability will similarly be
brought to vehicles.
Within the next 10 years, respondents expect a continuation and evolution of the above-
mentioned applications, in addition to some new ones. Potential new safety features include
fatigue detection and real-time parking information. From the roadside perspective, new
applications include signal change warnings, road condition alerts and more widespread
corridor deployment of roadside communication equipment units. In addition, the U.S.
Department of Transportation can be expected to encourage greater use of autonomous (or
semi-autonomous) vehicle safety applications to help eliminate driver error. These systems will
use varying combinations of electro-optical sensors, RADAR sensors and communications (for
cooperative systems) linked to ECUs and actuators.
24
6. Impact on Workforce Skills
The proliferation of electronics and electronic components in motor vehicles has been affecting
employers needs for skilled labor; these effects are expected to continue for the next five to 10
years. The changes are likely to affect the specific skill sets required, as well as the number of
workers and where they are likely to be needed. Advances in vehicle communications (as
represented by the USDOTs vehicle communication program) and efforts within the industry
(such as the Crash Avoidance Metrics Partnership) also indicate that electronics skills will be
needed in the public sector for deploying roadside equipment and the telecommunications
industry, for communications infrastructure. While much of this employment cannot be
attributed directly to the motor vehicle industry, it will affect the industry in terms of skills
needed to design, manufacture, maintain and repair in-vehicle communications equipment.
Today, this equipment is primarily represented by GM OnStar and Ford SYNC