Electronic Vehicle Management

Forward-looking vehicle management solutions

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Vehicle Control Units in commercial vehicles: Structure and diversity 2

Vehicle Control Units in commercial

vehicles: Structure and diversity.
Already today electrical and electronic architectures in commercial vehicles
are very complex: In the four main areas Powertrain, Chassis & Safety, Cabin &
Comfort and Infotainment & Telematics, a large number of electronic control
units (ECUs) operate simultaneously and are networked with several bus sys-
tems. Only through this interaction the required functional diversity, availability,
economy and convenience of modern commercial vehicles can be realized.

Additionally there are special control units containing Today and in the future, the division into domains
all the interfaces required by body manufacturers with one head unit each offers new potentials for
to control specific functions. The way in which an function integration, architecture simplification, cost
electrical/electronic architecture (E/E- architecture) is reduction and the integration of additional functions,
structured in a commercial vehicle varies considerably e. g. sensor-based driver assistance systems. Typical
depending on the vehicle manufacturer (OEM). examples are Adaptive Cruise Control (ACC), Lane
Departure Warning (LDW) and Blind Spot Detection
For all the diversity of topologies existing today, there (BSD). As these assistance systems also mean addi-
are also common features: control units for cab-based tional input for the control of driving dynamics, they
functions and the ECU of the vehicle management usually require an optimization of the E/E-architecture
system usually form clearly separated areas or in order to obtain economical control of an increased
domains, even if both are mounted in the cabin of complexity.
the vehicle. This structure is partially based on the
sometimes considerable cable length between the
(tilt) cab and the drive train components. A long cable
harness is a persistent source of errors in information
interchange.
Vehicle Control Units in commercial vehicles: Example of the decentralized electrical / e lectronic architecture for the future 3

Example of the decentralized electrical  /electronic architecture for the future.

High-Speed CAN [500 kBit/s]; CAN-FD [Flexible Datarate]; Ethernet

Powertrain Chassis Cabin Infotainment Gateway &

Master Control Unit Master Control Unit Master Control Unit Master Control Unit Computation

Engine Level & Roll

Door Modules MMI-CU VDR/DTCO
Management Control

Emission Tire Pressure Instrument

HVAC Tolling-OBU
Aftertreatment Monitoring Cluster

Battery & Energy Secondary

Body Builder Cabin l / Os
Management Display

General
Brake ADAS Sleeper l / Os
Purpose I / Os

Access Radio &

Retarder Body Builder
Control Navigation

Gearbox

Powertrain Chassis & Safety Cabin & Comfort Infotainment &

Domain * Domain * Domain Telematics Domain

Interdomain Backbone (High-Speed CAN, 500 kBit/s) Chassis Subnet (High-Speed CAN)
Redundant CAN Cabin Subnet (Low-Speed CAN)
USB Infotainment Subnet
Powertrain Subnet (High-Speed CAN) * Safety relevant
Optimal usage of domain controllers 4

Optimal usage of domain controllers.

The E / E-architecture of a modern commercial vehicle typically has a two-
stage structure: One control unit dedicated to each functional range gener-
ally is located as close as possible to the individual aggregates of the power-
train. Complexitiy and costs of the vehicle management can be significantly
reduced through full use of the vehicle control unit’s potential.

The powertrain related control units (ECUs) like en- The units can be manufactured and tested as com-
gine, clutch, transmission / retarder controller and / or plete modules (powertrain, chassis, cab) also simpli-
the brake systems (ABS / EBS) are interconnected via fying the complete production logistics process.
high-speed CAN buses.
The considerably reduced number of wirings
A modern vehicle architecture with a VCU (Vehicle results in cost benefits and quality improvement.
Control Unit) as powertrain master controller pro-
vides easy to test units and features clearly defined Ultimately the VCU provides a clearly structured con-
system interfaces and limits − this simplifies develop- trol system architecture for the increasing number
ment and production processes. of system components requesting dynamic torque
demands in modern vehicles.

Vehicle Management (VCU) Advantages at a glance

−−Vehicle dynamics application independent from development

cycles in engine and transmission

−−Wide system solution range

Platform control units with up to date Matlab® / Simulink®

based application tool chain
Specific customer solution for hardware and software

−−Compact cost optimized solution for cabin mounting IP 40

−−High performance microcontroller to perform complex

control applications

−−Short interfaces to haptic HMI (pedals, stalk switches) result

in improved EMC consistency

−−Different data interfaces

CAN low-speed up to
CAN high-speed and CAN FD (Flexible Data Rate)
Ethernet for automotive application
LIN bus
Optimal usage of domain controllers 5

Vehicle Management in the Vehicle Control Unit Centralization or decentralization?

To correctly coordinate the timing of the individual VCUs are indispensable for vehicle management and
control units, e. g. during a gear change, the individu­ therefore it is important to use these control units as
al ECUs of the powertrain are subordinate to a vehi- efficiently as possible. Depending on the individual
cle control unit. This dominant VCU is responsible for E/E-architecture it is possible to integrate previously
the entire powertrain domain and coordinates the separate installed ECUs into the VCU. The VCU then
control tasks of the individual control units. acts as the domain computer and can be designed
to be correspondingly powerful depending on the
Nevertheless the driver can always intervene via OEM’s requirements.
pedals, steering wheel buttons, and direct operating
switches, thus remaining the captain on board, while However, it is not possible to integrate an unlimited
all systems installed are for support only and to number of functions in a single control unit. Thus it
reduce driver’s workload significantly. is always worth considering in each individual case
whether the strategy provides for a higher integra-
tion per ECU or an optimized network with ECUs
divided up in accordance to related functions.

Vehicle Management – Data processing to assist the driver

Predictive
Man-Machine Interface ADAS-Sensors Drivetrain
Vehicle Management

Instrument Cluster Adaptive Cruise Control [ACC] Engine

Switches Lane Departure Warning Clutch

[LDW]

Steering Column Control Gearbox

−− Retarder Blind Spot Detection [BSD]
−− Cruise Control
Retarder

Pedals
−− Accelerator Pedal
−− Brake Pedal ABS / ASR
−− Clutch Pedal

Expansion

Modules for Body Builder OEM specific Vehicle Control Units

Platform Vehicle Control Units

Scalable Application Function

Libraries
Generic Vehicle Control Unit 6

Generic Vehicle Control Unit – Vehicle

management made easy.
In the late 1990s vehicle management as a separate control unit above the
engine controller was successfully established. In the meantime all major
heavy duty truck manufacturers have implemented this structure in a specif-
ic adapted hard- and software solution.

To make the benefits of a dynamic vehicle man- This Model Based Development System (MBDS) is a
agement available to our worldwide partners in seamless system solution to cover the whole V-Cycle
the commercial vehicle market Continental has of the development process. It includes the software
developed a universal platform hardware with all testing to ensure the software to be completely test-
necessary I / O features implemented. In addition, we ed on operating system level as well as with regard
offer a proven software development process based to developed application functionalities.
on MatLab® / Simulink® to ensure highest quality in
safe and reliable application function programming. The hardware design of the control unit is automo-
The programming is based on software tool chains tive qualified – guaranteeing the control unit to be re-
common to the transportation industry and can also liably operative. The software development process
be done by the commercial vehicle manufacturers is supported via MBDS down to system simulation to
themselves. ensure a completely tested operating system. Addi-
tionally Continental is providing support with basic
application function libraries to simplify developing
processes and support fast time to market solutions.

Generic Vehicle Control Unit Advantages at a glance

−−Proven software development process

based on MatLab® / Simulink®

−−Automotive qualified hardware design

−−Software function simulation for re-

duced testing time and cost-efficiency

−−Extensive basic function libraries to

support fast time to market solutions

−−Application support with basic function

libraries to ensure fast time to market
solutions

Universal platform hardware with all necessary

I / O features implemented.
Generic Vehicle Control Unit − System view and outlook 7

Generic Vehicle Control Unit − System view and outlook

Operation Controls
and Indicators
Body Builder CAN

Instrument CAN

Body Builder Central Board

Gearbox Retarder
Module Computer

Drivetrain CAN

ADAS
Brake Systems
Sensors

Outlook – Next evolutionary step

Multifunktional LIN bus AMT Selector

VCU
Steering Wheel Switch

Engine CAN

Engine Pedals Immobilizer

The dominant VCU is responsible for the entire LIN bus. The next evolutionary step is the addi-
powertrain domain and coordinates the control tional input of ADAS sensors and the advanced
tasks of the individual control units via CAN and control of brake systems via the VCU.
eHorizon® 8

eHorizon® – Knowing exactly what lies ahead.

While today’s ADAS-sensors are observing the actual environment in front of and
next to the vehicle, eHorizon® offers the possibility to look far ahead and even
“around the corner”. This “electronic horizon” allows vehicle and driver to cast an eye
on the road in front which is improving safe driving as well as opening up new possi-
bilities regarding fuel efficiency.

“In face of” an ascending slope of the road eHorizon® will be of great value to reducing the number of accidents and
take action: In case of a manual gearbox the driver will be therefore improving road safety especially in regard to the
advised to change the gear correspondingly. With auto- constantly rising density of traffic.
mated gearboxes and cruise control the gear change will
be optimized to achieve maximum fuel efficiency. In the future the vehicle will be connected to live infra-
structure-information sent by its surroundings, e. g. traffic
On top eHorizon® provides functionalities to significantly news, red light signals, information on accidents sent by
improve road safety, e. g. automatically reduced speed other vehicles etc. This collection of useful data will be the
when expecting a sharp curve, emergency braking in next step towards a safety increase in traffic and will help
case of upcoming hazardous situations or danger spots substantially to create a safe and clean urban environment
and speed limit warnings based on fixed road speed limits for future generations.
map data. Thanks to these functionalities eHorizon® can

eHorizon®

Advantages at a glance

−−Remarkable safety improvement The combination of AFFP® and eHorizon® can significantly improve road
safety and fuel efficiency providing the perfect overview of the actual and
−−Optimized fuel-efficiency upcoming road and traffic conditions.

−−Effective driver assistance

Accelerator Force Feedback Pedal 9

AFFP® – The direct line to the driver.

Electronic Accelerator Pedals came up with the need to evolve from a me-
chanic driver interface to full electronic control of the combustion engine.
This meant a large technological step on the way to realizing smooth control
of vehicles decoupled from the drivers wish to control the flow of fuel by
stepping onto the accelerator pedal.

Accelerator Force Feedback Pedal

Prediction & safety Safety Comfort & efficiency

When tailgating AFFP® will press Overdriving a speed limit (e. g. traffic Having the wrong gear selected AFFP®
against the driver’s foot to guide. sign) AFFP® will pulse to warn. will pulse to remind gear shifting.

Today the driver’s wish for acceleration/deceleration by pulsing his foot. This is a very fast possibility to
is only one of many requests among others based get in touch with the driver without any distraction.
on data derived from cruise control, eHorizon® or The driver’s reaction time is remarkably reduced
infrastructure information. compared to warning lamps or acoustic signals.
Therefore the AFFP® is the ideal warning system in
Following the idea of “force feedback” borrowed today’s high volume of traffic that requires prompt
from the computer games industry Continental action of the driver.
developed the Accelerator Force Feedback Pedal
(AFFP®). The pedal is used as tactile interface to in- In combination with eHorizon® AFFP® can signifi-
form or warn the driver about dangerous situations cantly improve safety and fuel efficiency.
Architecture optimization 10

Architecture optimization.
As more and more digital solutions replace the analog world in commer­-
cial vehicles, the freedom of the OEM grows to redefine or partition the
E / E-architecture. Thanks to high performance microcontrollers (e. g. Power
PC) and an increasing number of bus interfaces, the potential of the VCU
domain computer can be used in an extremely wide variety of ways.

ECU integration as a simplification strategy Integration of additional functions beyond the

To reduce the number of partner control units on powertrain
the powertrain, we have integrated the functions The VCU can also assume additional functions
for the differential locks for all wheel driven vehicles beyond the domain computer tasks such as:
during the further development of a current vehicle
controller. In the preceding architecture, this function −−the high degree of freedom of networks to inte-
was still designed as a separate ECU. grate body functions in a VCU (we have already
implemented this approach for a leading commer-
The highly integrated VCU unifies control and cial vehicle manufacturer)
management functions:
−−the direct control of safety-relevant signal lamps
−−for the engine and the interface for additional steering wheel
buttons
−−for transmission and permanent brakes
−−as gateway between all domains, the VCU passes
−−the traction control for several driven and on a large number of messages to less safety-rel-
steered axles evant electronic systems, e. g. to the instrument
cluster, the air conditioning, the fleet management
−−the engine thermal management with control or the radio
of additional aggregates and power take-offs
Managing hybrid bus drives
−−the recording of diagnostic and service data Today the “elite class” in the implementation of
electronic systems is indisputably the hybrid vehicle.
VCU performance requirements can be derived from In city buses, for example, a high-performance
the technical characteristics as follows: Designed in coordination level is required for overall manage-
32-bit technology with a mathematical coprocessor ment above the two drive levels of the diesel engine
that is used for the real-time processing of complex and the electric motor. We have also successfully
algorithms, ready for model-based development. developed this type of VCU under the designation
A multilayer PCB carries not only the multi-pin of Powertrain Control Unit (PCU). Beyond the central
µProcessor (416-pin PBGA), but also a large number management of driving dynamics, the PCU also as-
of electronic power switches for currents of up to sumes safety and emergency management and the
10 Ampere. A 150-pin connector and five CAN and recording of diagnostic and service data.
four LIN interfaces are used to connect the vehicle
environment.
Outlook 11

Outlook.
In the future it must remain an unprejudiced consid- The last decades in vehicle management show a
eration as to whether a higher integration is a better clear trend towards predictive vehicle management
solution, or whether ECUs separated according – realizing the possibility to look far ahead and even
to their functions are more suitable for a specific “around the corner”. Therefore new sensors like
vehicle. Anyway, more and more digital technology radar, cameras or “electronic horizon”-solutions are
is to be expected in commercial vehicles. And one installed, reacting much faster than any well trained
day possibly even a fully networked vehicle in which driver can ever do. These vehicle management
switches and buttons are no longer connected with solutions will produce an intelligent vehicle that is
individual wires, but instead via a standard data able to change the gear automatically before a hill
bus. Of course, this places especially high demands is reached, lower the speed in good time before
on both the computing speed and on the required the road bends, warn the driver when tailgating or
program and data memory. However, this reduces carry out an emergency braking in case of danger.
the total complexity and therefore the costs for the Trendsetting driveline dynamics control is going to
wiring harness in future vehicles, making it an advan- make future vehicles safer, more efficient, quiet and
tage for the customer and its competitiveness. eco-friendly and thus will take vehicles a step further
towards protecting our unique environment.

Predictive Vehicle Management – Next step to the assisted driver

Predictive
Man-Machine Interface ADAS-Sensors Drivetrain
Vehicle Management

Head Up Display [HUD] Adaptive Cruise Control [ACC] Engine

Instrument Cluster Lane Departure Warning Clutch

[LDW]

Switches Gearbox
Blind Spot Detection [BSD]

Steering Column Control Retarder

−− Retarder Map Data [eHorizon®]
−− Cruise Control

Pedals
−− Accelerator Force
Feedback Pedal [AFFP®]
−− Brake Pedal
−− Clutch Pedal Expansion Brake Systems

Communication Vehicle to OEM specific Vehicle Control Units ABS / ASR

−− Vehicle
−− Infrastructure
Platform Vehicle Control Units Electronic Brake System [EBS]

Modules for Body Builder

Scalable Application Function Advanced Braking
Libraries ­A ssistance [ABA]
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