4 Steering Braking PDF

Steering and Braking in Autonomous Driving
Maria Guitart Corominas

4th-5th October 2022
Steering & Braking in Autonomous Driving
Summary
A2Mac1 Automotive Benchmarking
Trends in Autonomous Driving & Considered Solutions
Strategies in Steering Systems
Strategies in Braking Systems
Conclusions
Steering & Braking in Autonomous Driving 4
Unmatched precision on a full-vehicle scale

Constantly increasing the level of granularity to understand the overall topology
Vehicle Level • Component Level Subcomponent Level Topologies & Architectures

• Vehicle acquisition • Vehicle disassembly (over 1500 • Further disassembly • Determine cross-system design
• General Specifications parts) • Documentation of sub-components considerations
• Concept Descriptions • 3D scanning & rendering • Insight on manufacturing processes , • Document electrical architecture &
• KPIs & Overview • Extensive documentation (weight, effort and procedure create block diagrams by harvesting
dimensions, material, supplier) • Additional analysis to define material data from pin-to-pin studies
grades
• Fully comprehensive documentation of
electronics content (BOM)
• 2D sections of crucial entities
Unmatched precision on a full-vehicle scale

Constantly increasing the level of granularity to understand the overall topology
Vehicle Level • Component Level Subcomponent Level Topologies & Architectures

• Vehicle acquisition • Vehicle disassembly (over 1500 • Further disassembly • Determine cross-system design
• General Specifications parts) • Documentation of sub-components considerations
• Concept Descriptions • 3D scanning & rendering • Insight on manufacturing processes , • Document electrical architecture &
• KPIs & Overview • Extensive documentation (weight, effort and procedure create block diagrams by harvesting
dimensions, material, supplier) • Additional analysis to define material data from pin-to-pin studies
grades
• Fully comprehensive documentation of
electronics content (BOM)
• 2D sections of crucial entities
Trends in Autonomous
Driving & Considered
Solutions
How much sensors for ADAS are mounted in an average vehicle?

Average number of Sensors
Ultrasonic sensors:
9.00
• Already commoditized in
Substantial increase of ADAS-sensors in an average vehicle today‘s vehicle. 8-12 sensors
8.00 +16.3% are used in most of the vehicles
7.00 +14.2%
-4.2%
+20.3%
6.00
Average number of sensors
Cameras:
• Strong increase of number of
5.00
cameras in recent years
• Further accelaration can be
4.00 expected in the upcoming years
+8.8%
+17.0% Radar:
3.00 +7.9% • Strong increase of number of
+54.1% radars in recent years
+16.3%
2.00 +6.6% +8.1%
+21.8%
LiDAR:
+59.3% • Solid-state radars begin to
1.00 +7.6%
appear in production vehicles.
• Will strongly come to market in
0.00 the next years
2000 2005 2010 2015 2020
Camera LiDAR Ultrasonic sensors Radar

Redundancy Strategies
How to realize a fallback solution
Past Practices
The Future
Sensing
External Input
Modules
Control Control Module

Control Complementary
with Internal or
Module Redundancy Module Verification ECU
Driver
Actuation Actuation Actuation

Module Module Module
ADAS redundancy approaches

Electronics
Tesla Model Y: Redundancy in computation chips

• 2x Tesla FSD chips for redundant sensor data processing
• Twice as much peripherie needed to ensure chip
functionality: power supply, memory, commodity
components
• Two independent power supply paths towards ADAS ECU
Lucid Air: Triple redundancy in ADAS ECU

• Three identical PCBs inside Lucid Air ADAS ECU with 1x
Nvidia Xavier on each chip
• Parallel processing of ADAS data on all three computation
boards
Conclusion: To ensure autonomous driving, the vehicle has to implement a certain degree of
redundancy to guarantee high degree of reliability and satisfactory performance even if a part of
the system is failing
Level 2.0 Autonomous Driving

Considered Platforms from the North American Market
Ford Blue Cruise GM SuperCruise Tesla Autopilot Lucid DreamDrive
• Available only on designated • System can be engaged in more • No activation restrictions • Blend of various sensing
‘Blue Zones’ locations • Able to follow highway interchanges modules, incl. Lidars
• No input from the side of rear of • GPS predictive functionality • Reliant on camera input • High-speed Ethernet ring
the vehicle as of now • Lane changes possible even • No efforts on driver monitoring electrical architecture
• Assisted lane changes in progress while towing • Decision validation between
dedicated ECU & software
control platform
Strategies in Steering Systems

Steering System
Peripheral elements involved with autonomous steering
ADAS ECU Torque & Angle sensor Driver
To be phased out
Steering Motor
How to ensure fail-safe

steering operation?
Steering System
Ford Mustang Mach-E Chevrolet Bolt Lucid Air Dream Edition Tesla Model Y
Steering System
Electronics - Board
Ford GM Lucid Air Tesla
Redundancy – 2 identical No redundancy

circuits Redundancy – 2 identical circuits Redundancy – 2 identical
circuits
➢ 2 independent power ➢ 2 independent power
supplies supplied by the supplies supplied by ➢ 2 independent power
same battery individual battery supplies (supplied by the
same battery)
➢ 2 sets of windings ➢ 4 set of windings
(connections to motor ➢ 1 set of windings
phases)
Steering System
Mechanics – Motor phases
6-phase 3-phase 12-phase 3-phase
➢ Normal operation using 6- ➢ Both circuits refer to the

➢ Normal operation using 12-
phases same 3-phases of the motor
➢ Only manual steering phase (assumption)
➢ Fail-safe mode enables to ➢ Fail-safe operation by
possible to bring the vehicle ➢ (Depending on the location
shut off one of the bridges switching off the defective
to a safe stop of the failure detected
and continue operation with inverter bridge and using the
(short circuted MOSFET)) 6-
50% of the power (3 phases) auxiliary circuit.
or 3-phase operation during
Higher ripple current ➢ Possibility of switching off
emergency time
(assumption) only one of the motor phases
Steering System
Electronics - Microcontroller
SAK-TC234L
SAK TC387QP-160 TMS570LS1224
Identical Microcontrollers
Different Microcontrollers
Identical Microcontrollers Single circuit ➢ Infineon 3 core TriCore 32-
➢ One unidentified IC from bit System on a Chip (SoC)
➢ Infineon 4 core TriCore 32- ➢ Texas Instruments 32-bit ➢ Lockstep operation mode
Toshiba, presumably acting
bit System on a Chip (SoC). Dual Core microcontroller possible
as a pre-driver for the motor
AURIX family. 10MB Flash ➢ Lockstep operation mode ➢ Up to ASIL D
and the microcontrollers
➢ Capable of Lockstep possible ➢ 45 degrees of rotation for
from Renesas.
operation mode the microcontroller and
➢ 45 degree rotation for one of
➢ ASIL D compliant capable some ICs. 90 deg rotation for
the microcontrollers
some ceramic capacitors
Steering System
Electronics – Sensor & Inverter
Double Hall effect sensor Double Hall effect sensor

➢ 2 Different position & angle Single Hall effect sensor Single Hall effect sensor ➢ 2 identical position & angle
sensor at either sides of the ➢ High precision Allegro ➢ Only one dedicated position sensor at either sides of the
board (both Infineon) Microsystems unit sensor from TDK corporation board (Allegro
Microsystems)
Bridge Inverter Bridge Inverter Bridge Inverter
➢ 9 MOSFETS per bridge ➢ 6 MOSFET arrangement from ➢ 3 Specific power modules per Bridge Inverter
➢ Different choice of Nexperia bidge. Problably capable of ➢ 9 MOSFETS per bridge
manufacturers per bridge current sensing (Toshiba)
(Infineon & NXP)
Steering
Vehicle level - BUS topology
➢ Typically shared BUS line between ADAS ECU, EPS motor, Brake Booster and ABS Pump (variability of additional connected devices such as
driver monitoring ECU (Ford Mustang Mach-E)
Ford Mustang Mach-E Tesla Model Y

Steering
Vehicle level - BUS topology
➢ Typically shared BUS line between ADAS ECU, EPS motor, Brake Booster and ABS Pump (variability of additional connected devices such as
driver monitoring ECU (Ford Mustang Mach-E)
➢ Tesla being the only vehicle opting for redundant BUS lines
Ford Mustang Mach-E (equivalent approach for Lucid Air and Chevrolet Tesla Model Y
Bolt)
ADAS ECU
ADAS CAN
ECU CAN
high high
speed speed
CAN
high
speed
EPS Motor
EPS Motor
EPS Motor
EPS Motor
Strategies in Braking Systems

Trends in Braking Systems

Integration & Decoupling
Numerous vehicles bridge the observed gap,
offering solutions integrating the master cylinder
and brake booster while the ABS pump remains an
independent entity
What is next?
Separate master cylinder, Integrated master

brake booster & ABS pump cylinder, brake booster, &
ABS pump
Reduce part count, weight complexity Shifting Point towards true brake-by-wire solutions

Current Market Leading Solutions:
Bosch Discrete Fail-Operational System Approach

➢ iBooster and the ESP brake control modules independently control brake
actuation
➢ In case of singular failure, the unaffected entity takes over to ensure a safe
stop while maintaining the ability to steer
Other contributors in the field

* Continental & ZF Promotional Material

The Next Step
MKC2
➢ Multi-logic architecture realized via two stand-alone pressure build-up modules
➢ The pedal is now fully decoupled from the pressure generating entities
➢ Enable topologies with the booster modules positioned away from the pedal
ZF Secondary Brake Module

➢ Auxiliary actuator for the hydraulic system in case of primary boost function
failure
Current Available Braking Solutions

Chevrolet Bolt, Tesla Model Y & Lucid Air ABS Pump
• 2 motor bridge driver ICs supplied by
STM indicate a need for external
current measuring in contrast to the
integrated custom solution seen in the
Lucid Air
• Duplication of crucial components
observed on the board
• Park brake functionality via

additional application-specific IC
supplied by STM
• 2 different versions of the same µC

by Texas Instruments seen on the
Tesla and GM vehicles, a Renesas
solution is seen for the Lucid
• Set of 2 fuses on each board
indicates redundant power supply

Lucid Air & Tesla Model Y Booster
Next generation µC by
Renesas with different
packaging & pin count
Different capacitors used

between product iterations
Additional H-Bridge
Different reverse battery Driver by STM
protection strategies
High Power 3 Phase

Bridge Driver
Similar but not quite the same!
Lucid’s version of the product integrates the parking brake functionality with a few adjustments on the board population

Chevrolet Bolt EUV Premier 2022 Booster
Hercules Microcontroller Power cut-off & reverse

Based on the ARM Cortex-R battery protection
Core by Texas Instruments
replaces Renesas solution
3-phase Bridge switches

incorporated to the lower
housing part
Bosch Customized Components

Presumed to be a system basis
IC interfacing with the
pressure sensor serving power
management, communication
& safety supervision
functionalities
A different approach!
Electronics mounted to structural parts

Mustang Mach E 3-in-1 Solution
• Sets of N-channel MOSFETS by Vishay along with a Dual N-channel

transistor by Infineon to realize the parking brake functionality
• 3 sets of 2 MOSFETs comprising the 3-phase B6 bridge
• IC to drive the bridge
• Only application with flash memory, 64 Mb SPI flash IC by Spansion
• Board is populated by customized ICs tailored for the application
supplied from:
➢ STMicroelectronics
➢ Presumably Infineon, bearing Ate Branding (ASIC)
➢ NXP
• Linear hall FET sensor

• Redundant linear position sensor
in the form of a PCBA
Case Study: Brake Booster

Brake Booster Market Benchmark

Integrated Solutions - Overview
Hyundai Ioniq5 Ford Mustang Mach-E
Chevrolet Trailblazer Chevrolet Suburban

32

Mobis iMEB2 Conti. MKC1
High-Level Comparison
Mobis iMEB2 Continental MKC1 Bosch IPB ZF/TRW IBC
Comparison Scenario,
Korea 250k, 2022
Manufacturer Mobis Continental Bosch ZF / TRW
Production site Korea Germany Germany US

Inverter KPI
Bosch IPB
Weight [kg] 5.265 5.791 5.178 7.033
ZF/TRW IBC
Overall Dimension [mm³] 213 x 210 x 295 232 x 195 x 355 180 x 183 x 342 215 x 222 x 390
$$
Total Cost [250k p.a.]

33

Cost Breakdown
• Electronic module is consisting • The Hydraulic control unit of

of PCBAs, Coils and Housing. the Mobis solution has no
Brake Fluid Reservoir -Hydraulic Control additional functionality, in
• It has the highest contribution Overhead + Profit Assembly unit contrast to other solutions.
15% 2%
to the cost of the system in all 16%
brake boosters Total Production • Continental MK C1 has brake

12%
Motor Assembly lever cylinder and master
11% cylinder integrated.
• Bosch IPB has master cylinder,

MOH brake lever cylinder and air
3% accumulator tank integrated in.
Master Cylinder • ZF/TRW IBC hydraulic control

8%
unit apart from the master
Electronic cylinder and brake pedal
Module cylinder has the brake pedal
33%
simulator as an additional
These five assemblies will be considered during the integrated feature.
benchmark:
Reservoir, Hydraulic Block, Motor, Master Cylinder,
ELECTRONIC Electronic HYDRAURIC CONTROL
MODULE UNIT
34

Example: Hydraulic Control Unit Benchmark
Mobis Hydraulic Control Unit: Continental Hydraulic Control Unit:
• Dimensions: 130 x 58 x 88 mm³ • Dimensions: 157 x 121 x 91 mm³

Weight: 892 g Weight: 1776 g
Material Aluminum Material Aluminum
• Additional functionalities: • Additional functionalities:
• 15 valves / 4 different types • 14 valves / 2 different types

• Cylinder housing is not integrated • Has RPM sensor and pressure vent integrated in
• 2 pressure sensors • 2 pressure sensors
Bosch Hydraulic Control Unit: ZF/TRW IBC Hydraulic Control Unit:
• Dimensions: 141 x 121 x 65 m³ • Dimensions: 150 x 130 x 95 mm³

Weight: 1363g Weight: 1885 g
Material Aluminum Material Aluminum
• Additional functionalities: • Additional functionalities:
• 14 valves / 4 different types • 14 valves / 3 different types

• Has an air accumulator tank and pressure vent integrated in the • There is a brake pedal simulator integrated
housing • 2 pressure sensors
• 2 pressure sensors
35

Example: Rotor Benchmark
Mobis Rotor Continental Rotor
• Stack, 50c800, 49 Sheets: • Neodymium Sinter Magnets

weight: 229.7g (with overmolded magnets) • Straight Rotor Shaft
dimensions Ø 47.41x79.16 mm³ • Stack: 52 Disks, 0.65 mm, 1.5g/Disk Required
price: 5.272 $ weight: 78g
• Magnets are Overmolded dimensions: Ø 27.5x85 mm³
• Price: 6.144 $ Price: 0.43$
• Magnets are Overmolded (14 Magnets)
• Price: 6.837 $
Bosch Rotor ZF Rotor

• Rotor Shaft:
• Stack. 42 sheets: weight: 120 g
weight: 136.2 g dimensions: Ø 42x46 mm³
dimensions Ø 46.85 x 22.72 mm³ price: 3.225
price: 1.015 $ • Magnets are glued to the rotor and covered by a foil (10
• Magnets are slid in the Rotor (8 Magnets) Magnets)
• Price: 5.067 $ • Price: 7.549 $
• The production of shaft involves processes such as turning
(24s cycle time) and Broaching (12s cycle time) that are the
cost drives.
36

Example: Main PCBA Benchmark
Mobis Continental Bosch ZF-IBC
Number of main
1 1 1 1
PCBAs
Dimensions 182x124x1.6 172x149x1.6 149x125x1.72 172x163x1.54
Number of Layers 8 8 6 6
Cu Thickness [µm] 70/35 105/70 70/70 105/105

Main PCB
Surface Treatment Imm.Sn Imm.Sn Imm.Sn Imm.Sn

Number of
components on the 426 276 256 566
top
Number of
components on 187 420 239 13
the bottom
PCB cost W/O components

$$
PCBA total
*PCBA Cost indicates cost of PCBs as well as all the mounted components
37

Main Desing Highlights
Mobis Continental Bosch ZF
• Has a single functionality No • Different parts are integrated • Different parts are integrated • Production is more complex.
extra integration inside the • Has 14 Valves but of only 2 • Has 4 different types of valve • Different parts are
hydraulic Block. different types same as Bosch integrated
Hydraulic block • Has one Valve more than other and ZF • 3 types of valves
brake boosters
• The housing is die casted and it • Housing is deep drawn • Housing is deep drawn • Has an Expensive Housing
is expensive • Has a RMP sensor that needs • Rotor magnets assembly is the • Stator uses sets of stacks that
• The stator has a low-cost extra gearing system simplest. need to be welded together
design • Magnets are overmolded • For Rotor, The magnets first
Motor • Rotor has a simple design need to be glued then covered
by a foil
• Cylinder is not integrated in • Has a highly integrated cylinder • Has a highly integrated cylinder • Cylinder has many parts and
and needs extra housing • Complex design for master the design is more complex.
Cylinder • Relatively simple design cylinder • Has an extra Die casted base
which is expensive
• Motor Angle sensor integrated • Has 2 micro controllers • Has 4 types of PCBAs, • Has 2 micro controller
in the main PCBA • Inductor/ Capacitors inserted • Has only 2 types of coils • Housing base has many parts
• Simple Housing in the Housing • Simple housing integrated
• Has 4 types of coils • Housing Top is Deep Drawn • Housing Top is Deep Drawn.
Electronics
• Main PCBA is expensive • No hall sensor for travel sensor
Conclusions
Conclusions
Despite not being required to achieve ADAS level 2, indications of fail-safe designs can be
observed, in anticipation of autonomy levels 2.5 – 3 and above:
• Steering Systems:
• Hardware redundancy efforts in electronics, mechanical and vehicle level
➢ Power supply, microcontrollers (Lockstep operation), inverter bridge, sensing unit…
➢ Higher number of phases in the actuator
➢ Communication Buses, redundancy in the 12V battery
• Broad spectrum of propososed solutions within the considered options in terms of design
and presumably also in cost
• Braking Systems:
• Currently focusing around refinements & integration of functionalities, improving spacing
& flexibility
• Redundancy-relevant efforts mainly around the pedal positioning aspect
• 1st indication of module duplication to take place down the line
Encuesta de opinión
Sesión 4 Steering and braking
1. https://doi.org/10.4271/2002-01-0266
2. https://www.bosch.com/stories/redundant-systems-automated-driving/
3. https://www.bosch-mobility-solutions.com/en/solutions/driving-safety/ibooster/
4. https://www.zf.com/products/en/cars/products_64252.html
5. https://www.continental-automotive.com/en-gl/Passenger-Cars/Technology-Trends/Electric-Vehicle/MK-C2
6. http://en.btl-auto.com/index.php/WCBS/
7. Kelling, Nico A., and Worthy Heck. “The BRAKE Project - Centralized Versus Distributed Redundancy for Brake-by-Wire Systems.” SAE Transactions, vol. 111,
2002, pp. 141–50. JSTOR, http://www.jstor.org/stable/44699407. Accessed 1 Jul. 2022.

4 Steering Braking PDF

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

4 Steering Braking PDF

Uploaded by

Copyright:

Available Formats

Steering and Braking in Autonomous Driving

Maria Guitart Corominas

A2Mac1 Automotive Benchmarking

Trends in Autonomous Driving & Considered Solutions

Strategies in Steering Systems

Strategies in Braking Systems

Unmatched precision on a full-vehicle scale

Vehicle Level • Component Level Subcomponent Level Topologies & Architectures

Unmatched precision on a full-vehicle scale

Vehicle Level • Component Level Subcomponent Level Topologies & Architectures

How much sensors for ADAS are mounted in an average vehicle?

Camera LiDAR Ultrasonic sensors Radar

Control Control Module

Actuation Actuation Actuation

ADAS redundancy approaches

Tesla Model Y: Redundancy in computation chips

Lucid Air: Triple redundancy in ADAS ECU

Level 2.0 Autonomous Driving

Ford Blue Cruise GM SuperCruise Tesla Autopilot Lucid DreamDrive

Strategies in Steering Systems

ADAS ECU Torque & Angle sensor Driver

How to ensure fail-safe

Redundancy – 2 identical No redundancy

6-phase 3-phase 12-phase 3-phase

➢ Normal operation using 6- ➢ Both circuits refer to the

Double Hall effect sensor Double Hall effect sensor

Ford Mustang Mach-E Tesla Model Y

Strategies in Braking Systems

Trends in Braking Systems

Separate master cylinder, Integrated master

Trends in Braking Systems

Bosch Discrete Fail-Operational System Approach

Other contributors in the field

* Continental & ZF Promotional Material

Trends in Braking Systems

ZF Secondary Brake Module

Current Available Braking Solutions

• Park brake functionality via

• 2 different versions of the same µC

Current Available Braking Solutions

Different capacitors used

High Power 3 Phase

Current Available Braking Solutions

Hercules Microcontroller Power cut-off & reverse

3-phase Bridge switches

Bosch Customized Components

Current Available Braking Solutions

• Sets of N-channel MOSFETS by Vishay along with a Dual N-channel

• Linear hall FET sensor

Case Study: Brake Booster

Brake Booster Market Benchmark

Hyundai Ioniq5 Ford Mustang Mach-E

Chevrolet Trailblazer Chevrolet Suburban

Brake Booster Market Benchmark

Mobis iMEB2 Continental MKC1 Bosch IPB ZF/TRW IBC

Manufacturer Mobis Continental Bosch ZF / TRW

Production site Korea Germany Germany US

Total Cost [250k p.a.]

Brake Booster Market Benchmark

• Electronic module is consisting • The Hydraulic control unit of

brake boosters Total Production • Continental MK C1 has brake

• Bosch IPB has master cylinder,