Browse Topic: Electronic control units

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Synthesis, characterization and electro active properties of poly (Meta Toudine-co-Fluro aniline) Ag dispersed nanocomposites: Shielding Composite as surface Coat or Enclose the ECU Housing for preventing signal distortion and ensuring reliable engine performance2026-28-0022To be published on 02/12/2026
A series of electroactive nanocomposites of silver dispersed poly (metatoludine-co-o-fluroaniline) copolymer has been prepared by in-situ polymerization method. The chemical molecular structures are identified by using UV–visible spectra, FTIR, X-ray diffraction instruments, SEM analysis. We propose that these composite materials possess a Electromagnetic Shielding interference coat or enclose the engine control unit (ECU) housing in the form of surface coating or moulded shell in order to prevent signal distortion and ensuring reliable engine performance in automobiles. This composite material possesses lightweight, corrosion-resistant EMI shielding solution for ECU housings. Implementation of these products significantly reduced signal interference from nearby high-power electronics, ensuring stable engine operation. The proposed system offers a cost-effective, lightweight alternative to metallic shielding in vehicular electronics in automobile industries.
Pachanoor, Vijayanand, Kumar, V
Automotive Ethernet Proxy-Based Security Architecture In Vehicle Computers2026-28-0121To be published on 02/01/2026
Modern vehicles require sophisticated, secure communication systems to handle the growing complexity of automotive technology. As in-vehicle networks become more integrated with external wireless services, they face increasing cybersecurity vulnerabilities. This paper introduces a specialized Proxy based security architecture designed specifically for IP-based communication within vehicles. The framework utilizes proxy servers as security gatekeepers that mediate data exchanges between Electronic Control Units (ECUs) and outside networks. At its foundation, this architecture implements comprehensive traffic management capabilities including filtering, validation, and encryption to ensure only legitimate data traverses the vehicle's internal systems. By embedding proxies within the automotive middleware layer, the framework enables advanced protective measures such as intrusion detection systems, granular access controls, and protected over-the-air (OTA) update channels. This strategy
M, Arvind, Praneetha, Appana Durga, Remalli, Ravi Teja
Standard SWS Requirement based Integration testing for classic AUTOSAR modules2026-26-0507To be published on 01/16/2026
In the development of the automotive electronic control unit (ECU), to keep performance at the desired level, what remains constant is to verify, evaluate, and validate electronic control units. Nowadays, Cars have multiple ECUs even in the range of fifty. Software is validated by a tester using a target ECU, Controller Area network (CAN) communication, and some Input/Output simulation techniques. Also, in some applications, a virtual environment is created for testing. In this paper, the method of Integration testing of Automotive Open System Architecture (AUTOSAR) modules is presented with AUTOSAR software specification as its input. This makes standard test cases as SWS remains the same for AUTOSAR standard release. It enables a platform to efficiently test all layers of AUTOSAR base software (BSW) modules after integration. For the demonstration, TriCore micro controller TC377TX from Infineon is used. Same controllers are usually used in the development of automotive ECUs for
Kelkar, Renu, Patil, Vardhman
Hardware in Loop Validation of Rotary Switch with TFT Display2026-26-0540To be published on 01/16/2026
The increasing complexity of modern automotive drive control systems necessitates the adoption of robust validation methods to ensure functional safety, reliability and customer satisfaction. This paper presents the development and implementation of a comprehensive Hardware-in-the-Loop (HIL) testing framework designed specifically for a specific ECU known as Gear Selection Switch (GSS)/Drive control switch (DCS) system. Hardware-in-the-Loop (HIL) Testing is a simulation-based testing technique where real physical hardware (like an electronic control unit, switch or sensor) is tested by connecting it to a virtual simulation of the rest of the system — instead of testing it inside a real vehicle. Following the analysis of all the field failure incidents reported till date for GSS, detailed root cause investigations were conducted using in-house testing and Ishikawa diagram analysis. A critical failure mode was identified and addressed through targeted mechanical design modification and
Bhuyan, Anurag, Jahagirdar, Shweta, Khandekar, Dhiraj
Shaping the Future of Mobility with Innovative Power Tailgate Testing Solutions2026-26-0473To be published on 01/16/2026
Abstract With increasing demand for automation and user convenience in modern vehicles, Power Operated Tailgates (POT) have become standard in premium and mid-segment cars. However, validating such systems—comprising electronic control units (ECUs), sensors, actuators, and mechanical components poses significant challenges in safety, reliability, and cost. This paper introduces a Hardware-in-the-Loop (HiL) based validation framework that allows comprehensive, automated, and safe testing of POT systems without depending on full vehicle prototypes. The HiL platform integrates Real Time Hardware and Real Time software with dynamic models to simulate real-world behaviors. It enables automated validation of normal and fault scenarios—such as open/close commands, anti-pinch protection, voltage sensitivity, and communication errors—ensuring robust system performance. The proposed framework accelerates development, improves test coverage, and supports early fault detection, making it a
More, Shweta, Ghanwat, Hemant, Shetti, Suraj, Jape, Akshay, Kulkarni, Shraddha, Jagdale, Nitin
EV Powertrain Systems Diagnostics & Prognostics utilizing AI & ML (LLM) based approach2026-26-0664To be published on 01/16/2026
This study introduces a novel Large Language Model (LLM)-driven approach for comprehensive diagnosis and prognostics of vehicle faults, leveraging Diagnostic Trouble Codes (DTCs) in line with industry-standard automation protocols. The proposed model represents a significant advancement in automotive diagnostics by not only identifying fault codes but also reasoning through the root causes behind them, thereby enhancing fault interpretability and maintenance efficiency. The LLM is trained on extensive service manuals, sensor datasets, historical fault logs, and OEM-specific DTC definitions, enabling context-aware understanding and correlation of faults. Analytical validation has been performed using real-world vehicle datasets from multi-brand platforms, demonstrating the model’s ability to detect complex fault chains and accurately predict probable root causes. By utilizing time series based projection of vehicle pattern, model could also predict the potential future faults basis the
Pandey, Suchit, Joshi, Pawan, Kondhare, Manish, CH, Sri Ram, Gajbhiye, Abhishek, S, Adm Akhinlal
AI based models as Virtual sensors to replace real sensors2026-26-0671To be published on 01/16/2026
Artificial Intelligence and Machine learning models have a large scope and application in Automotive embedded system. These models are used in automotive world for various applications like calibration, simulation, predictions etc. These models are generally very accurate and play the role of a virtual sensor. However, the AI/ML models are resource intensive which makes them difficult to execute on a largely optimized automotive embedded systems. The models also need to follow safety standards like ASIL-D. The current work involves creating a Global DoE with ASCMO to generate data from a 125cc single to create AI/ML model for the engine outputs like Torque, T3, Midcat temperatures etc. The created models were validated across the operating space of the engine and found to have good accuracies. With AI Coder, the torque and T3 prediction AI models were converted to embedded code which can be easily used as a virtual sensor in real time. Using these AI models, accurate predictions can be
Chouhan, Vineet Singh, Bulandani, Saurabh, Kumar, Alok, Varsha, Anuroopa, P R, Renjith
Cross-ICA Trust Mechanism in Automotive Cybersecurity2026-26-0615To be published on 01/16/2026
With the ever increasing complexity and connectivity in modern vehicles, cybersecurity has become an indispensable technology. In the era of Software Defined Vehicles (SDVs) and Ethernet-based architectures, robust authentication between Electronic Control Units (ECUs) is critical to establish a trust. Further, the cloud connected ECUs must perform authentication with backend servers. These authentication requirements often demand multiple certificates to be provisioned within a vehicle, ensuring secure communication between various combinations of ECUs. As a result, a single ECU may end up storing multiple certificates, each serving a specific purpose. This work proposes a method to limit the number of certificates required in a given ECU without compromising security. We introduce a Cross-Intermediate Certificate Authority (Cross-ICA) Trust Architecture, which enables the use of a single certificate per ECU for inter-ECU communication as well as backend server authentication. In this
Venugopal, Vaisakh, Goyal, Yogendra, Raja J, Solomon, Rai, Ajay, Rath, Sowjanya
Feasibility and Performance of Post-Quantum Cryptography on Embedded Systems for Two-Wheeler Security2026-26-0622To be published on 01/16/2026
The proliferation of connectivity features (V2X, OTA updates, diagnostics) in modern two-wheelers significantly expands the attack surface, demanding robust security measures. However, the anticipated arrival of quantum computers threatens to break widely deployed public-key cryptography (RSA, ECC), rendering current security protocols obsolete. This paper addresses the critical need for quantum-resistant security in the automotive domain, specifically focusing on the unique challenges of two-wheeler embedded systems. This work presents an original analytical and experimental evaluation of implementing selected Post-Quantum Cryptography (PQC) algorithms, primarily focusing on NIST PQC standardization candidates (e.g., lattice-based KEMs/signatures like Kyber/Dilithium), on microcontroller platforms representative of those used in two-wheeler Electronic Control Units (ECUs) – typically ARM Cortex-M series devices characterized by limited computational power, memory (RAM/ROM), and strict
Mishra, Abhigyan
Risk Based Security Monitoring Framework for CAN network2026-26-0616To be published on 01/16/2026
There is rapidly increasing advancement in Connectivity, Autonomous, Subscription and Electrification features in vehicles which are being developed. These trends have resulted in an increase in attack surface and security risks on vehicles. To handle these growing risks, it has become important to include passive security systems such as Intrusion detection systems (IDS) which can detect successful or possible attempts of intrusion into vehicle systems compromising their security. In vehicles based on Zonal Architecture, two types of IDS can be implemented, Network based IDS (NIDS) and Host Based IDS (HIDS). The NIDS is implemented in Gateway Electronic Control Unit (ECU) and can monitor multiple networks connected to Gateway, whereas the HIDS usually monitors one single host ECU. Extensive research material is available on NIDS for CAN Networks. For example, the CAN Network in a vehicle is monitored for various abnormal behaviours such as increased busload and invalid signal values
E L, Nanda Kumar, Mutagi, Megha, Sonnad, Preeti, Sharma, Dhiraj
Lightweight AI Deployment for Legacy Automotive ECUs: A Practical Optimization Approach2026-26-0663To be published on 01/16/2026
Automotive systems are increasing adopting data-driven and intelligent functionality in the areas of predictive maintenance, virtual sensors and diagnostics. This has led to a need for the AI models to be directly run on vehicle ECUs. However, most of these ECUs – especially those in cost-sensitive or legacy platforms lack the computational capacity and parallel processing support required for standard AI implementations. Given the stringent real-time and reliability requirements in automotive environments, deploying such models presents a unique challenge. This paper proposes a practical methodology to optimize both the training and deployment phases of AI models for low-computation ECUs that operate without parallelism. Designing lightweight model architectures, using pruning and quantization techniques to minimize resource utilization, and putting in place a strategy appropriate for single-threaded execution are the three main objectives of the developed approach. The goal is to
Sharma, Sahil, Mathew, Melvin John
Impact of Virtual ECUs on Software Development and Validation Using the Shift Left Strategy2026-26-0681To be published on 01/16/2026
The automotive industry is undergoing a transformative shift with the integration of Virtual Electronic Control Units (vECUs) in software development and validation processes. Physical ECUs require actual hardware setups, which can be expensive, time-consuming to configure, and may not be readily available during early development stages. This abstract presents the application of a Level 3 vECU to enable early-stage testing in alignment with the Shift Left Strategy, thereby reducing development time and cost. The developed vECU includes production-intent code for the Application Software (ASW), Runtime Environment (RTE), Basic Software (BSW), and Operating System (OS), while adapting the Microcontroller Abstraction Layer (MCAL) and Complex Device Drivers (CDD) for the virtual environment. The vECU replicates the functional behavior of a physical ECU and supports standard automotive communication protocols such as CAN, LIN, Ethernet and FlexRay, allowing system-level validation in a
Bhopi, Amey, Sengar, Bhan
MOSAIC-TARA: A Comprehensive TARA Methodology for Automotive Cybersecurity2026-26-0609To be published on 01/16/2026
Threat Analysis and Risk Assessment (TARA) is a continuous activity, acting as a foundation of cybersecurity analysis for electrical and electronics automotive products. Existing TARA methodologies in the automotive domain exhibits challenges due to redundant and manual processes, particularly in handling recurring common assets across Electronic Control Units (ECUs) and functional domains. Two primary approaches observed for performing TARA are Manual-Asset-Centric TARA and Catalogue-Driven TARA. Manual-Asset Centric TARA is constructed from scratch by manually identifying the assets, calculating risks by likelihood, and impact determination. Catalogue-Driven TARA utilizes the precompiled likelihood and impact against identified assets. Both approaches lack standardized and modular mechanisms for abstraction and reuse. This results in poor scalability, increased efforts, and difficulty in maintaining consistency across vehicle platforms. The proposed method in this research overcomes
Goyal, Yogendra, Sinha, Swati, Sutar, Swapnil, Jaisingh, Sanjay
Virtual ECU: Development & Validation Platform2026-26-0683To be published on 01/16/2026
Vehicle software is moving towards software-centric architectures and hence software-defined vehicles. With this transition, there is a need to handle various challenges posed during development and validation. Some of the challenges include unavailability of hardware limiting the evaluation of various hardware options, board bring-up and hence leading to delays in software development targeted for the hardware, eventually leading to delayed validation cycles. To overcome the above challenges, we present in this whitepaper a virtual ECU (vECU) framework integrated with a CI/CD pipeline. A Virtual ECU (Electronic Control Unit) is a software-based emulation of a physical ECU. The adoption of virtual ECUs empowers development teams to commence software development prior to the availability of physical hardware. Multiple tools are available to demonstrate virtual ECUs, for example, QEMU, Synopsys, QNX Cabin, etc. vECU setup, when paired with a CI/CD pipeline, allows continuous integration
Singh, Jyotsana, Shaikh, Arshiya, Mane, Rahul, Burangi, Piyush
Dynamic Diagnostic Controller Architecture for Scalable and Adaptive Zonal Based Vehicle Platforms2026-26-0689To be published on 01/16/2026
The rapid evolution of in-vehicle electronic systems toward zonal and High-Performance Computing (HPC)-based architectures introduces a new layer of complexity in automotive diagnostics. Traditional architectures, built on Controller Area Network (CAN) and Local Interconnect Network (LIN) protocols, operate on a uniform Real-Time Operating System (RTOS), enabling simplified and consistent diagnostic workflows across Electronic Control Units (ECUs). However, next-generation platforms must accommodate diverse communication protocols (e.g., CAN, LIN, DoIP, SOME/IP) and heterogeneous operating systems (e.g., RTOS, Linux, QNX), resulting in fragmented and inflexible diagnostic processes. This paper presents a Centralized Diagnostic Gateway architecture that addresses these challenges by enabling unified, scalable, and adaptive diagnostic capabilities across modern vehicle platforms. The proposed system consolidates protocol handling at the HPC level, abstracts diagnostic complexities, and
Mukherjee, Soumyadeep, Raman, Kothanda
Achieving Robust Sensing Performance for Six-Airbag Systems: Design Approaches and Validation Techniques for Side Sensing2026-26-0030To be published on 01/16/2026
The introduction of GSR 16(E) in India mandates six airbags in passenger vehicles, aiming to enhance occupant safety. In parallel, the new Bharat New Car Assessment Program (BNCAP) outlines performance protocols that demand robust airbag deployment strategies to achieve a five-star safety rating. One of the critical challenges in meeting both regulatory and consumer safety expectations is the optimal packaging of the airbag Electronic Control Unit (ECU) and its associated impact sensors. These must perform reliably across regulatory tests, BNCAP protocols, and real-world accident scenarios. The location of side acceleration ‘g’ side impact sensors—whether mounted on the side sill, B-pillar, C-pillar, or door structures—is pivotal to achieving consistent and timely airbag deployment. These sensors must also demonstrate immunity to false triggers or missed events in both static and dynamic misuse and abuse conditions. Ensuring robust sensor performance under these varied conditions is
Kudale, Shailesh, Rao, Guruprakash, wayal, Virendra, Goswami, Tarun
Resilient Design Strategies for Wireless Charger ECUs: A Proactive Threat Analysis and Risk Assessment Framework for Ensuring Cybersecurity in EV Charging Ecosystems2026-26-0173To be published on 01/16/2026
The goal of Automotive cybersecurity is safety, reliability, confidentiality and authenticity. As the automotive industry grows smarter, so too do the cybersecurity protocols used to protect vehicles from malicious actors. Automotive cybersecurity secures communication networks, electronic systems, software and data collected by the new wave of intelligent cars The paper describes the cyber security threats its analysis ion wireless charging
Uthaman, Sreekumar, Mulay, Abhijit B, Gadekar, Pundlik
Development of an Optimized XCP Software Stack for Real-Time Validation of Vehicle Control Units Using Next-Generation Communication Protocols2026-26-0190To be published on 01/16/2026
In EVs, todays trend is to integrate power conversion and traction inverter subsystems by ensuring the increase in reliability and improvement in efficiency and cost effectiveness. The increased safety requirement poses risk of maintaining safety standards and increase in cost and time for manufacturing. The main integrated EV systems consists of Onboard charger, DC -DC converter and PDU. Each of the components and software is continuously evolving and it requires to be tested and validated in cost effective manner. The paper describes the design and development of XCP (Universal Measurement and Calibration Protocol) software stack for connecting calibration systems to electronic control units. The Software stack help in the read and write variable in the memory content of the microcontroller at run time. It’s a network Protocol Originated From ASAM. The software stack is easy to understand and platform independent, allowing it to be used on any microcontroller
Uthaman, Sreekumar
LLM-Driven Automotive Body Controls Design Optimization: A Case Study Focused on Cost and Time Waste Elimination2025-36-0142To be published on 12/18/2025
This paper addresses the challenge of increasing hardware complexity, long development cycles and high costs associated with integrating multiple systems. The research explores the potential of Large Language Models (LLMs) when applied as chatbots to revolutionize the design and development of automotive electrical hardware systems, encompassing areas such as convenience features, safety systems, advanced lighting, vehicle body control and modular electronic control units. A key focus is on how LLMs can automate cost-reduction design tasks, including design optimization, requirements verification and component validation, ultimately driving down expenses without compromising performance or reliability. Furthermore, the research investigates how LLMs can assist in decision-making by providing data-driven insights that inform critical design choices and facilitate enhanced team collaboration, leading to improved productivity through innovative tools and streamlined workflows. In that
Ribeiro, Riquelmy Oliveira de, Souza Santos, Gabriella de, Batista, Victor Gnoatto, Peres, Renan Luis Cassiano, Santos, Jean Carlo Villares dos, Ferreira, Flávio Fabrício V. M., Murari, Thiago B.
Vehicle Electrical Architecture: A Review of Wiring Harness Routing Optimization Strategies2025-36-0130To be published on 12/18/2025
The modern vehicle electrical architecture consists, on average, of 30 integrated electronic modules (ABS, infotainment, instrument panel, etc.), also known as Electronic Control Units (ECUs), and approximately 300 peripherals such as sensors (collision, temperature, oxygen, position, pressure, etc.) and actuators (window motor, mirror motor, relays, airbag inflator, windshield wiper, etc.). This increase in component integration imposes significant challenges to system installation and design. The interconnection of multiple devices renders harness design an arduous and time-consuming task, especially when conducted manually, resulting in error-prone and suboptimal outcomes. Such a scenario highlights the pressing need for studies on harness routing optimization in the automotive industry. Historically, wiring harness design practices have transitioned from manual approaches to the adoption of advanced computational tools. This methodological transition encompasses the use of various
Ribeiro, Thiago, Reis, Breno, Barreto, Zeus, Galeno, Antônio, Pereira, Marcelo, Ferreira, Fláavio Fabrício V. M.
Influence of Supply Voltage over Fuel Injector’s Deadtime2025-36-0174To be published on 12/18/2025
This study presents three methods for obtaining the latency of an indirect injection Electro-Injector as a function of the applied voltage. This parameter is relevant for the linearization of the injected mass in order to model fuel mass delivery on modern ECUs. For this purpose, the authors built a test bench, with the intent of running analysis on the results of tests of mass differential between injections, circulating current, and mechanical vibration. The authors gathered data over the iterative experiments and correlated the mass differential, vibration data and current measurements. The authors observed that with a reduction of supply voltage at the injector’s pins, a greater injector dead time made itself present displaying a need for a compensation of opening time in function of voltage since the injector’s needle takes a longer amount of time in partially open positions. Modern ECU manufacturers broadly use the data obtained by this type of iterative experiment to accurately
Juliatti, Rafael Motter, Oliveira, Julia Mathias de, Morais Hanriot, Sérgio de, Silveira, Hairton Júnior Jose da, Moreira, Vinicius Guerra
Lumped Parameter Thermal Network for Automotive Components: Modeling, Simulation, System Identification, and Parameter Estimation2025-01-507811/28/2025
This research paper proposes a framework based on lumped parameter thermal networks (LPTN) to understand the system behavior of thermally stressed component spaces in automotive vehicles. LPTNs offer an energy-based, low-degree-of-freedom model that can represent arbitrary thermal systems inside automotive vehicles. The time response of these low-order models can be calculated using standard ordinary differential equation solvers. The paper showcases the modeling of LPTNs and the calculation of their time response by using an electronic control unit (ECU) of a BMW 7 series. The use of LPTNs instead of exponential functions reduced the MAE in this example by 60.5%. Furthermore, a system identification approach for experimental temperature curves has been developed and implemented. System identification aims to mathematically model system behavior and predict system output. This paper compares least-square estimation (LSE) with constrained minimization (CM), where CM has a higher MAE by
Kehe, Maximilian, Enke, Wolfram, Rottengruber, Hermann
Hardware Protected Security Environment – Trusted Application Isolation Security ModelsJ3101-2_202511 (Current)11/17/2025
This information report identifies and evaluates isolation building blocks applicable to TA sandboxing within a HPSE. These building blocks can be used to support SAE J3101 TA requirements for sandboxing of TAs and secure communication between TAs. TAs must execute within their own trust domain to prevent compromise of the HPSE and other TAs. TA trust domain isolation strength may vary depending on the risk profile of the TA deployed, hence the requirement for isolation building blocks to match the risk profile. A multitenancy TA HPSE has a higher risk profile than multiple TAs from the same source (e.g., OEM). TA multitenancy must not compromise the security properties of the HPSE (the secure integration and execution of trusted multi-vendor code). In this report, we provide information on the following: HPSE TA use cases and risk profiles HPSE TA isolation building blocks for manufacturers Threat analysis to determine the effectiveness of isolation security models As the ECU E/E
Vehicle Electrical System Security Committee
Cybersecurity: Applying Threat Modeling to Sensor-Control Architectures in Autonomous Off-Highway Vehicles2025-28-031611/06/2025
The rapid evolution of autonomy in Off-Highway Vehicles (OHVs)—spanning agriculture, mining, and construction—demands robust cybersecurity strategies. Sensor-control systems, the cognitive core of autonomous OHVs, operate in harsh, connectivity-limited environments. This paper presents a structured approach to applying threat modeling to these architectures, ensuring secure-by-design systems that uphold safety, resilience, and operational integrity.
Kotal, Amit
Knock Sensors for Two Wheelers Applications2025-32-007911/03/2025
This paper describes the design and characteristics of the knock sensor. The sensor is already used as a commodity product for automotive applications and used by all automotive OEMs for spark ignited combustion engines. With the arrival of the electronic fuel injection on the two wheelers, further optimization of the combustion can be obtained. Although there are many publications on the engine knock strategy, little is known publicly about the sensor itself. The knock sensor is an accelerometer based on a piezoelectric component; it provides an analog signal of the engine vibration. The Electronic Control Unit will filter the signal according to a specific strategy and defines the presence and intensity of the engine knock. The ECU will act accordingly on the ignition timing. The inner structure as well as the mechanical and electrical interface are described in this article.
van Est, Jeroen, Prieu, Corentin
Development of an Artificial Calibrator for Shift Program Optimization to Enhance Fuel Efficiency2025-32-008211/03/2025
The calibration of automotive electronic control units is a critical and resource-intensive task in modern powertrain development. Optimizing parameters such as transmission shift schedules for minimum fuel consumption traditionally requires extensive prototype testing by expert calibrators. This process is costly, time-consuming, and subject to variability in environmental conditions and human judgment. In this paper, an artificial calibrator is introduced – a software agent that autonomously tunes transmission shift maps using reinforcement learning (RL) in a Software-in-the-Loop (SiL) simulation environment. The RL-based calibrator explores shift schedule parameters and learns from fuel consumption feedback, thereby achieving objective and reproducible optimizations within the controlled SiL environment. Applied to a 7-speed dual-clutch transmission (DCT) model of a Mild Hybrid Electric Vehicle (MHEV), the approach yielded significant fuel efficiency improvements. In a case study on
Kengne Dzegou, Thierry Junior, Schober, Florian, Rebesberger, Ron, Henze, Roman
Electronic Control Units for Enhanced Safety and Monitoring2025-01-504007/03/2025
The rapid evolution of electric vehicles (EVs) necessitates advanced electronic control units (ECUs) for enhanced safety, monitoring, and performance. This study introduces an innovative ECU system designed with a modular architecture, incorporating real-time monitoring, cloud connectivity, and crash sensing. The methodology includes cost-effective design strategies, integrating STM32 controllers, CAN bus systems, and widely available sensors for motor RPM and temperature monitoring. Key findings demonstrate that the proposed ECU system improves data reliability, enhances vehicle safety through crash response systems, and enables predictive maintenance via cloud connectivity. This scalable and affordable ECU is adaptable to a broad range of EV models.
Padma Priya, S.R., Santhipkumar, S., Sasipriya, S., Srivisweswara, M.S.
ZT4SDV Dynamic Trust for SW Defined Vehicles*2025-01-808404/01/2025
Today’s vehicle architectures build trust on a framework that is static, binary and rigid; tomorrow’s software defined vehicle architectures require a trust model that is dynamic, nuanced, and adaptive. The Zero Trust paradigm supports this dynamic need, but current implementations focus on protecting information, not considering the challenges that automobiles face interacting with the physical world. We propose expanding Zero Trust for cyber-physical systems by weighing the potential safety impact of taking action based on information provided against the amount of trust in the message and develop a method to evaluate the effectiveness of this strategy. This strategy offers a potential solution to the problems of implementing real-time responses to active attacks over vehicle lifetime.
Kaster, Robert, Ma, Di
The Effects of Collision-Related Power Loss on Toyota Safety Sense 2.5+ Event Data2025-01-871304/01/2025
Toyota vehicles equipped with Toyota Safety Sense (TSS) can record detailed information surrounding various driving events, including crashes. Often, this data is employed in accident reconstruction. TSS data is comprised of three main categories: Vehicle Control History (VCH), Freeze Frame Data (FFD), and image records. Because the TSS data resides in multiple Electronic Control Units (ECUs), the data recording is susceptible to catastrophic power loss. In this paper, the effects of a sudden power loss on the VCH, FFD, and images are studied. Events are triggered on a TSS 2.5+ equipped vehicle by driving toward a stationary target. After system activation, a total power loss is induced at various delays after activation. Results show that there is a minimum time required after system initiation in order to obtain full VCH, FFD, and image records. Power losses occurring within this time frame produce incomplete records. Data accuracy is unaffected, even in partial records.
Getz, Charles, DiSogra, Matthew, Spivey, Heath, Johnson, Taylor, Patel, Amit
Daytime and Nighttime Performance Evaluations of the Automatic Emergency Braking and Forward Collision Warning Systems on a 2020 and 2022 Kia Telluride2025-01-869904/01/2025
Testing was conducted in daytime and nighttime conditions to evaluate the performance of the Automatic Emergency Braking and Forward Collision Warning systems present on both a 2020 and 2022 Kia Telluride. The 2022 Kia Telluride was tested during the day at speeds between 35 and 70 miles per hour, while the 2020 Kia Telluride was tested both during the day and at night at speeds between 35 and 60 miles per hour (mph). The daytime testing of both the 2020 and 2022 Kia Telluride utilized a foam stationary vehicle target. The nighttime testing of the 2020 Kia Telluride utilized a live 2006 Chevrolet Tahoe as the target with the brake lights on. Testing measured the Time to Collision (TTC) values of the visual/audible component of the Forward Collision Warning (FCW) that was presented to the driver. Further, testing also quantified the timing and magnitude of the two-phase response of the Automatic Emergency Braking (AEB) system. The results of both sets of testing add higher speed FCW and
Harrington, Shawn, Patrick-Moline, Peyton, Nagarajan, Sundar Raman
An Evaluation of the Performance of the Automatic Emergency Braking and Forward Collision Warning System in a 2020 Jeep Grand Cherokee during Daytime and Nighttime Conditions2025-01-869804/01/2025
Testing was conducted to evaluate the performance of the 2020 Jeep Grand Cherokee’s Forward Collision Warning (FCW) and Automatic Emergency Braking (AEB) collision mitigation systems at speeds between 35 and 70 miles per hour (mph). Two different 2020 Jeep Grand Cherokee’s were utilized under varying testing conditions in order to evaluate the performance of their collision mitigation systems. A total of 40 tests were conducted: 29 tests were conducted during daytime and 11 tests were conducted at nighttime. Testing measured the Time to Collision (TTC) values of the visual/audible component of the Forward Collision Warning that was presented to the driver. In addition, the testing quantified the TTC response of the Automatic Emergency Braking (AEB) system including the timing and magnitude of the automatic braking response. The results of the testing add higher speed FCW and AEB testing scenarios to the database of publicly available tests for the 2020 Jeep Grand Cherokee.
Harrington, Shawn, Lieber, Victoria, Nagarajan, Sundar Raman
Using CAN Electrical Signals for Cybersecurity and Harness Diagnostics2025-01-808004/01/2025
This paper describes a novel invention which is an Intrusion Detection System based on fingerprints of the CAN bus analogue features. Clusters of CAN message analogue signatures can be associated with each ECU on the network. During a learning mode of operation, fingerprints can be learnt with the prior knowledge of which CAN identifier should be transmitted by each ECU. During normal operation, if the fingerprint of analogue features of a particular CAN identifier does not match the one that was learnt then there is a strong possibility that this particular CAN identifier’s message is symptomatic of a problem. It could be that the message has been sent by either an intruder ECU or an existing ECU has been hacked to send the message. In this case an intruder can be defined as a device that has been added to the CAN bus OR a device that has been hacked/manipulated to send CAN messages that it was not designed to (i.e. could be originally transmitted by another device). It could also be
Quigley, Christopher, Charles, David
Designing Software for SAE J1939 ECUs to Improve Cybersecurity2025-01-808204/01/2025
SAE J1939 is a CAN-based standard used for connecting various ECUs together within a vehicle. There are also some related protocols sharing many of the features of SAE J1939 across other industries including ISO11783, RVC and NMEA 2000. The standard has enabled the easy integration of electronic devices into a vehicle. However, as with all CAN-based protocols, several vulnerabilities to cyberattacks have been identified and are discussed in this paper. Many are at the CAN-level, whilst others are in common with those protocols from the SAE J1939 family of protocols. This paper reviews the known vulnerabilities that have been identified with the SAE J1939 protocol at CAN and J1939-levels, along with proposed mitigation strategies that can be implemented in software. At the CAN-level, the weaknesses include ways to spoof the network by exploiting parts of the protocol. Denial of Service is also possible at the CAN-level. At the SAE J1939-level, weaknesses include Denial of Service type
Quigley, Christopher
LLM-Powered Fuzz Testing of Automotive Diagnostic Protocols2025-01-809104/01/2025
Modern vehicles contain tens of different Electronic Control Units (ECUs) from several vendors. These small computers are connected through several networking busses and protocols, potentially through gateways and converters. In addition, vehicle-to-vehicle and internet connectivity are now considered requirements, adding additional complexity to an already complex electronic system. Due to this complexity and the safety-critical nature of vehicles, automotive cyber-security is a difficult undertaking. One critical aspect of cyber-security is the robust software testing for potential bugs and vulnerabilities. Fuzz testing is an automated software testing method injecting large input sets into a system. It is an invaluable technique across many industries and has become increasingly popular since its conception. Its success relies highly on the “quality” of inputs injected. One shortcoming associated with fuzz testing is the expertise required in developing “smart” fuzz testing tools
McShane, John, Celik, Levent, Aideyan, Iwinosa, Brooks, Richard, Pesé, Mert D.
Synchronizing Real-Time Control in Centralized Automotive E/E Architectures2025-01-807204/01/2025
Automotive technologies have been rapidly evolving with the introduction of electric powertrains, Advanced Driver-Assistance Systems (ADAS) and Over-The-Air (OTA) upgradability. Existing decentralized architectures are not an optimal choice for these applications, due to significant increases in cost and complexity. The transition to centralized architectures enables heavy computation to be delegated to a limited number of powerful Electronic Control Units (ECUs) called domain or zone controllers. The remaining ECUs, known as smart actuators, will perform well defined and specific tasks, receiving new parameters from the dedicated domain/zone controller over a network. Network bandwidth and time synchronization are the two major challenges in this transition. New automotive standards have been developed to address these challenges. Automotive Ethernet and Time Sensitive Networking (TSN) are two standards that are well-suited for centralized architectures. This paper presents a
Ayesh, Mostafa, Bandur, Victor, Pantelic, Vera, Wassyng, Alan, Wasacz, Bryon, Lawford, Mark
Electronic Control Unit Hardware Design Challenges for Software Defined Vehicle2025-01-813604/01/2025
Software Defined Vehicle (SDV) is gaining attraction in the automotive industry due to its wide range of benefits like remote software/feature upgrade, scalable functionality, Electronic Control Unit (ECU) commonization, remote diagnostics, increased safety, etc. To obtain all these benefits, ECUs need to be designed accordingly. ECU hardware must be designed to support a range of vehicles with a variety of loading, scalable features, power distribution, levels of processing, and networking architecture. Each domain has unique challenges to make the ECU economical and robust to operating conditions without compromising performance. This paper illustrates the critical hardware design challenges to accommodate a scalable SDV architecture. This paper focuses electrical interface design to support wide range of input/output port loads, scalable functionality, and robust diagnostics. Also, flexibility of microprocessor processing capability, ECU networking, and communication complexity are
Hasan, S.M. Nayeem, Irgens, Peter
Model-Driven Systems Engineering Automation with Artificial Intelligence for Robustly Writing Automotive System Requirements2025-01-865804/01/2025
The intensive use of software applications in modern vehicles has highlighted the critical role of Systems Engineering (SE) in the automotive industry. These “computers on wheels” are thoroughly interconnected, by their own connections and with the cloud, due to the advancement of Electronic Control Units (ECU) technologies and the widespread use of sensors transmitting real-time data. This interconnectedness and the level of software abstraction that are known today, significantly escalates the complexity of these systems. This has made it necessary to adopt an approach that is flexible to change, structured, agile, and traceable. The modern approach to SE, now model-based, offers numerous advantages over the previous paradigm, which was predominantly document-based. MBSE (Model-Based Systems Engineering) emerges as a contemporary approach, providing the scalability needed for engineering teams to develop robust products. Its “model-based” essence ensures that the model acts as the
Mendes de Oliveira, Arthur Hendricks, Reis, Pedro Almeida, Anunciação, Gabriel, Vinícius Carlos de Lima, Jonathan, Sarracini Júnior, Fernando, Garcia, Matias Ezequiel
Vehicle Application LayerJ1939/71_202502 (Current)02/25/2025
The SAE J1939 communications network is developed for use in heavy-duty environments and is suitable for horizontally integrated vehicle industries. The SAE J1939 communications network is applicable for light-duty, medium-duty, and heavy-duty vehicles used on-road or off-road, and for appropriate stationary applications which use vehicle-derived components (e.g., generator sets). Vehicles of interest include, but are not limited to, on-highway and off-highway trucks and their trailers, construction equipment, and agricultural equipment and implements. SAE J1939-71 is the SAE J1939 reference document describing SAE J1939 parameter (SP) and message (PG) definitions, SLOT (standard data encoding) definitions, conventions and notations used to specify the parameter (SP) placement in PG data, conventions for text data parameters, and conventions for PG transmission rates. This document previously contained the majority of the SAE J1939 OSI application layer data parameters and messages for
Truck and Bus Control and Communications Network Committee
Application of Servo-Assisted Technology in Commercial Vehicle Steering Systems for Autonomous Mobility in Off-Road Trucks. Case Study: Application on 8x2/8x4 Sugarcane Trucks2024-36-003312/20/2024
The exponential growth of the agribusiness market in Brazil combined with the high receptivity among farmers of new technological solutions has driven the study and implementation of high technology in the field. This work aimed to apply servo-assisted driving technology to enable autonomous mobility in an off-road sugarcane truck responsible for harvesting sugarcane. The technology consists of a conventional hydraulic steering with a motor, ECU and torque and angle sensors responsible for reading input data converted from GPS signals and previously recorded tracking lines. The motor responsible for replacing 100% of the physical force generated by the driver acts in accordance with the required torque demand, and the sensors combined with the ECU correct the course to meet the follow-up line through external communication ports. The accuracy of the system depends exclusively on the accuracy of the GPS signal, in this case reaching 2,5 cm, which is considered extremely high accuracy
Oliveira Santos Neto, Antídio, Lara, Vanderlei, Silva, Everton, Destro, Daniel, Moura, Márcio, Borges, Felipe, Haegele, Timo
Deployment of Continuous Integration and Continuous Testing in Mobility for Software Qualification Test2024-28-019812/05/2024
In the rapidly evolving field of automotive engineering, the drive for innovation is relentless. One critical component of modern vehicles is the automotive ECU. Ensuring the reliability and performance of ECU is paramount, and this has led to the integration of advanced testing methodologies such as Hardware-in-the-Loop (HIL) testing. In conjunction with HIL, the adoption of Continuous Integration (CI) and Continuous Testing (CT) processes has revolutionized how automotive ECU are developed and validated. This paper explores the integration of CI and CT in HIL testing for automotive ECU, highlighting the benefits, challenges, and best practices. Continuous Integration and Continuous Test (CI/CT) are essential practices in software development. Continuous Integration process involves regularly integrating code changes into the main branch, ensuring that it does not interfere with the work of other developers. The CI/CT server automatically build and test code whenever a new commit is
Hande, Sheetal Vikram, Mandava, Balaji Bharath
MBSE for SDV: A Framework for Efficient Resource Allocation and System Behavior in Software Defined Vehicle2024-28-025512/05/2024
Emergence of Software Defined Vehicles (SDVs) presents a paradigm shift in the automotive domain. In this paper, we explore the application of Model-Based Systems Engineering (MBSE) for comprehensive system simulation within the SDV architecture. The key challenge for developing a system model for SDV using traditional methods is the document centric approach combined with the complexity of SDV. This MBSE approach can help to reduce the complexity involved in Software-Defined Vehicle Architecture making it more flexible, consistent, and scalable. The proposed approach facilitates the definition and analysis of functional, logical, and physical architecture enabling efficient feature and resource allocation and verification of system behaviour. It also enables iterative component analysis based on performance parameters and component interaction analysis (using sequence diagrams).
Navas, Akhil, Paul, Annie
Adaptive Machine Learning-Based Energy Management System for Hybrid Electric Vehicles2024-01-510812/02/2024
This paper examines the effectiveness of optimizing energy management in hybrid electric vehicles by integrating adaptive machine learning algorithms with the energy management electronic control unit (ECU). Existing traditional rule-based energy management and control strategies of power distribution between internal combustion and battery struggle to adapt to dynamic driving conditions, such as rapid acceleration, frequent stop-and-go traffic, and varying terrain. These scenarios often result in sub-optimal energy utilization and performance, as the fixed rules struggle to account for the immediate demands and inefficiencies that arise in such conditions. In conditions like that, rapid acceleration demands a sudden increase in power, which can lead to inefficient fuel consumption if not managed properly, while frequent stop-and-go traffic conditions can cause the battery to drain and lead to increased fuel consumption. Varying terrain can also lead to improper power distribution
Bhargav, Matavalam
Safety Concepts for Future Electromechanical Brake Central Control Systems15-18-01-000410/25/2024
Electromechanical brakes (EMB) are currently coming into focus in the automotive industry. This trend was confirmed in 2022, when a first automotive supplier [1] announced the series production of EMB systems. One major driver is safety, especially if EMB systems are implemented with smart actuators that install redundant electronic control units (ECU) and distributed software [1]. Earlier, the authors have addressed safety mechanisms in EMB actuators [2]. In this article the authors extend their investigation to address safety mechanisms in future EMB central control systems (CCS). Impact of different brake system topologies (X-, H-, centralized) vis-à-vis potential safety mechanisms within communication buses and ECUs is analyzed.
Schrade, Simon, Röhler, Andreas, Nowak, Xi, Verhagen, Armin, Schramm, Dieter
Coherix's computer-vision system improves electronics manufacturing24AUTP10_0810/01/2024
An industry-first 3D laser-based, computer-vision system can monitor and control the application of adhesive beads as tiny in width as two human hairs. This unique inspection system for electronic assemblies operates at speeds of 400 to 1,000 times per second, considerably quicker and more effective than conventional 2D systems. “Difficulty in precisely dispensing adhesives or sealants, especially in extremely small or complex electronic assemblies, can lead to over-application, under-application, bubbles, or incorrect location of the adhesive bead,” Juergen Dennig, president of Ann Arbor, Michigan-headquartered Coherix, told SAE Media. Improper application of joining material on electronic control units (ECUs) and power control units (PCUs) can result in poor adhesion, material voids and short circuits.
Buchholz, Kami
In-Vehicle Evaluation of a Rule-based Look Ahead Controller for Mobile Air Conditioning: Impact on Energy Savings2024-28-011209/19/2024
Energy efficiency in both internal combustion engine (ICE) and electric vehicles (EV) is a strategic advantage of automotive companies. It provides a better user experience that emanates amongst others from the reduction in operation expenses, particularly critical for fleets, and the increase in range. This is especially important in EVs where customers may experience range anxiety. The energetical impact of using the air conditioning system in vehicles is not negligible with power consumptions in the range of kilowatts, even with a stopped vehicle. This becomes particularly important in areas with high temperature and humidity levels where the usage of the air conditioning systems becomes safety factor. In such areas, drivers are effectively forced to use the air conditioning system continuously. Hence, the air conditioning system becomes an ideal choice to deploy control strategies for optimized energy usage. In this paper, we propose and implement a control strategy that allows a
Jaybhay, Sambhaji, Kapoor, Sangeet, Kulkarni, Shridhar Diliprao, Palacio Torralba, Javier, Locks, Olaf
An Efficient and Secure Wireless Controller Area Network for Autonomous Vehicle2024-01-508909/02/2024
Controller area network (CAN) buses, the most common intravehicle network (IVN) standard, have been used for over 30 years despite their simple architecture for connecting electronic control units (ECUs). Weight, maintenance costs, mobility promotion, and wired connection complexity increase with ECU count, especially for autonomous vehicles. This paper aims to enhance wired CAN with wireless features for autonomous vehicles (AVs). The proposed solutions include modifying the traditional ECU architecture to become wireless, implementing a hidden communication environment using a unique complementary code keying (CCK) modulation equation and presenting a strategy for dealing with jamming signals using two channels. The proposed wireless CAN (WCAN) is validated using OPNET analysis for performance and reliability. The results show that the bit error rate (BER) and packet loss of the receiver ECU are stable between different CCK modifications, indicating the robustness of the basic
Ibrahim, Qutaiba, Ali, Zeina
Engineering Autonomous Mobility: Wired and Wireless CAN Bus Design Principles14-14-01-000207/15/2024
The controller area network (CAN) bus, the prevailing standard for in-vehicle networking (IVN), has been used for more than four decades, despite its simple architecture, to establish communications between electronic control units (ECUs). Weight, maintenance overheads, improved flexibility, and wiring complexity escalate as the quantity of ECUs rises, especially for high-demand autonomous vehicles (AVs). The primary objective of this study is to examine and discuss the significant challenges that arise during the migration from a wired CAN to a wireless CAN (WCAN). Suggested remedies include changing the configuration of the conventional ECU, creating a hidden wireless communication domain for each AV, and developing a plan to counteract the jamming signals. The simulation of the proposed WCAN was done using MATLAB and validated using OPNET analysis. The results showed that the packet loss of the eavesdropping electronic control unit ranged from 63% to 100%. Anti-jamming results show
Ali, Zeina, Ibrahim , Qutaiba
Neural Network Modeling of Black Box Controls for Internal Combustion Engine Calibration2024-01-299507/02/2024
The calibration of Engine Control Units (ECUs) for road vehicles is challenged by stringent legal and environmental regulations, coupled with short development cycles. The growing number of vehicle variants, although sharing similar engines and control algorithms, requires different calibrations. Additionally, modern engines feature increasingly number of adjustment variables, along with complex parallel and nested conditions within the software, demanding a significant amount of measurement data during development. The current state-of-the-art (White Box) model-based ECU calibration proves effective but involves considerable effort for model construction and validation. This is often hindered by limited function documentation, available measurements, and hardware representation capabilities. This article introduces a model-based calibration approach using Neural Networks (Black Box) for two distinct ECU functional structures with minimal software documentation. The ECU is operated on
Meli, Matteo, Wang, Zezhou, Bailly, Peter, Pischinger, Stefan
A New Design Rule of Engine Coolant Pump in ICEs Focused to Energy Consumption Reduction2024-37-001506/12/2024
Engine thermal management systems represent a promising solution to improve the efficiency of current Internal Combustion Engines (ICE) and sustain the transition towards a net zero scenario. The core component of an engine thermal management system is the electric pump, which can adjust the coolant flow rate according to the engine thermal needs. This possibility opens to newer design choices, which can contribute to non-negligible energy savings. In this study, three electric coolant pumps with different maximum efficiencies have been investigated to understand the influence of the design operating conditions on the pump energy absorption. A reference vehicle equipping a 130 HP downsized gasoline engine has been considered. An experimental test bench with a copy of the engine and its cooling circuit has been reproduced, and the electric pumps have been tested at a wide range of rotational speeds and thermostat lifts to obtain their characteristic maps. Once their performances were
DI BARTOLOMEO, MARCO, Di Battista, Davide, Cipollone, Roberto, Fremondi, Fabrizio, Camagni, Umberto
NXP S32 CoreRide Platform simplifies development of software-defined vehicles24AUTD05_1005/01/2024
A new industry-first open platform for developing the software-defined vehicle (SDV) combines processing, vehicle networking and system power management with integrated software. NXP Semiconductors' new S32 CoreRide Platform was designed to run “multiple time-critical, safety-critical, security-critical applications in parallel,” Henri Ardevol, executive vice president and general manager of Automotive Embedded Systems for NXP Semiconductors, told SAE Media. NXP's new foundation platform for SDVs differs from the traditional approach of using multiple electronic control units (ECUs), each designed to handle specific vehicle system control tasks. Since each unit requires its own integration work, the integration workload exponentially increases with each additional ECU on a vehicle.
Buchholz, Kami
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