20140128 cisec-continental-automotive-electronics-development-and-assurance

CISEC January 28th 2014 Electronics development and assurance

Automotive Electronics

Jean-Pierre Loncle

www.continental-corporation.com Interior Division

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BU Body & Security January 28, 2014

2 Continental Automotive GmbH

› Since 1871 with headquarters in Hanover, Germany

› Sales of €32.7 billion

› 169,639 employees worldwide

› 291 locations in 46 countries

› One of the top 3 in the automotive supplier industry

Continental Corporation Overview 2012

Chassis & Safety 21%

Powertrain 19%

Interior 20%

Tires 29%

ContiTech 11%

Sales by division in %

Status: December 31, 2012

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3

January 28, 2014

Continental Automotive GmbH

Continental Corporation Five Strong Divisions

Powertrain

Engine Systems

Transmission

Hybrid Electric

Vehicle

Sensors &

Actuators

Fuel Supply

Interior

Instrumentation &

Driver HMI

Infotainment &

Connectivity

Body & Security

Commercial Vehicles

& Aftermarket

Tires

PLT,

Original Equipment

PLT, Repl. Business,

EMEA


The Americas


Asia Pacific

Commercial

Vehicle Tires

Two Wheel Tires

ContiTech

Air Spring Systems

Benecke-Kaliko

Group

Compounding

Technology

Conveyor Belt

Group

Elastomer Coatings

Fluid Technology

Power Transmission

Group

Vibration Control

PLT – Passenger and Light Truck Tires

Chassis & Safety

Vehicle Dynamics

Hydraulic

Brake Systems

Passive Safety &

Sensorics

Advanced Driver

Assistance Systems

(ADAS)

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Business Unit Body & Security Product Overview (main products only)

January 28, 2014


Intelligent Antenna Module

TPMS Sensor (valve mounted)

Car Key/ID

Start-Stop

Button

Immobilizer

eTIS Sensor (tire mounted)

DC/DC Converter

Seat Control Unit Pneumatic Seat System

Window/Door

and Sunroof

Control Unit

RKE &

PASE

Control Module

Central Gateway

LED/Lighting and

AFS Control Unit

Central Body

Control Module

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› Custom parts: most of the products are custom to fit OEMS specific requirements and EE architecture

› High volume: Some parts are exceeding 1Mio Unit / year

› Flexibility: Stick to customer needs

› Logistics for purchased parts

› Logistics for finished parts

› Manufacturing volumes, real time adaptation (JIT policy)

› Lifetime: standard is 15 years or 220 000 km

› Management of part change notification, part termination notice

› Quality target: Single digit ppm (part per million) for 0 km failure

› Short response time for failure analysis: 30 days associated to a 8D documentation to identify root cause, corrective actions and prevent reoccurence

› Automotive Environment requirements: Watertighness, Immunity to disturbances, Low EMC radiation level, Resistance to fluids, Low current consumption for Permanent Battery supplied parts (<1 mA)…

Automotive product development Automotive product constraints

January 28, 2014


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› G40 Target: Starts the detailed development

› G50 Target: Product design is completed

› G55 Target: Starts ordering of components and sourcing of production equipment

› G60 Target: Starts set up of production line

› G70 Target: Ready for PPAP

› G80 Target: Starts series production

› G90 Target: Series production running

› Each Gate has to be released prior to enter in next project phase.

Automotive product development Project Cycle and Quality gates

January 28, 2014


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› Upfront validation of new components, technologies and processes prior to Mass Production

› Motto: Never develop a novelty with the scope of an application project.

› Leading to:

› Base development for new technical solutions (eg: new custom component)

› Design Of Experiment (DOE) for Technology and process

› Eg: DOE for pressfit technology

› Eg: DOE for leadfree solder paste selection to cope with RoHS regulation

Automotive product quality development How to achieve Quality targets (pre development phase)

January 28, 2014


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› To secure component quality and performances by achieving Automotive Electronics Council (AEC) Q100 (for Active components) Q200 (for Passive components) requirements.

› By adding application oriented specific requirements:

Or Specific Supplier Quality agreements

› By continuously monitoring supplier / technology / component quality performances

› Supplier Audit and 3 level of approvals: Supplier Approval, Component Approval, Manufacturing Approval

Automotive product quality development How to achieve Quality targets

January 28, 2014


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› To successfully product DV (Design Validation) and PV (Product / Production Validation) on

top of design verification

› Representative DV/PV tests (Environmental):

Automotive product quality development How to achieve Quality targets (Development and PV Phases)

January 28, 2014


Standard reference Solid Tightness IEC 60529 Liquid tightness Water test ISO/DIS 16750-4 Salt spray IEC 60068-2-52 Kb Corrosive atmosphere IEC 60068-2-60 Ke Thermal shocks endurance test IEC 60068-2-14 Na Thermal shocks pre-ageing test IEC 60068-2-14 Na Warm storage IEC 60068-2-2 B Cold storage IEC 60068-2-1 A Climatic sequence IEC60068-2-38 Z/AD Temperature range (steps) test ISO/DIS 16750-4 Temperature range (steps) test ISO/DIS 16750-4 Cold operation IEC 60068-2-1 A Cold and low pressure storage IEC 60068-2-40 Z/AM Withstand voltage test ISO/DIS 16750-2 Insulation resistance test ISO/DIS 16750-2 Check of saturation temperature Specific Thermal cycling life test Specific Constant humid heat life test Specific Thermal life & combined road actuation

endurance Specific Free fall test IEC 60068-2-32 Ed: Free-fall Collision impact test IEC 60068-2-27 Ea : Shock Endurance to driving shocks test IEC 60068-2-27 Ea : Shock Falling tool shock test Specific Curbstone shocks test IEC 60068-2-29 Eb: Bump Brackets and fasteners resistance test Specific Terminal strength test Specific Resonance-point detecting point Specific Resonance-point oscillation test IEC 60068-2-6 Fc Random vibration endurance test IEC 60068-2-64 Fh

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› Representative DV/PV tests (Electrical & EMC):

Automotive product quality development How to achieve Quality targets (Development and PV phases)

January 28, 2014


Standard reference Resistance to pulse 1 bis ISO 7637-2 Resistance to pulse 2a ISO 7637-2 Resistance to pulse 3a ISO 7637-2 Resistance to pulse 3b ISO 7637-2 Resistance to pulse 5a or 5b ISO 7637-2

Resistance to power supply micro-interruptions ISO16750-2 Resistance to starting profile ISO16750-2

Resistance to on-board power system voltage ripples ISO16750-2 Immunity to signal line transients ISO 7637-3 Immunity to bulk current injection (BCI) ISO 11452-4 Immunity to bulk current injection (BCI) ISO 11452-4

Resistance of inductive load connected circuits Specific Resistance to impulsive transient Specific Immunity to radiated field ISO 11452-2

Immunity to audio frequency magnetic field ISO 11452-8 Resistance to electrostatic discharges, equipment not

supplied IEC 61000-4-2 Resistance to electrostatic discharges, equipment

supplied ISO 10605 Resistance to handy transmitters ISO11452-9

Measurement of conducted transient emission ISO 7637-2

Measurement of audio frequency conducted emission Specific

Measurement of radio frequency conducted emission CISPR 25

Measurement of radio frequency radiated emission CISPR 25

Measurement of magnetic field radiated emissions MIL-STD 461 E Resistance to power supply voltages ISO16750-2 Resistance to slow decrease and increase power of

suply voltages ISO 16750-2. Re-initialization test ISO16750-2

Resistance to non usual power supply voltages ISO16750-2 Resistance to ground and positive supply voltages

short circuit ISO16750-2 Safety switch compatibility Specific

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› Capability (Cpk) analysis

› Test results drift analysis

› Process step FPY analysis and improvement

› Non conform parts analysis

› Safe Launch plan

› Products and component traceability

› PPAP submission and customer audit

Automotive product quality development How to achieve Quality targets (manufacturing phase)

January 28, 2014


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› Design FMEA (Failure Mode Effect Analysis)

› Process FMEA

› Worst case analysises

› FMEDA (Failure Mode Effects and Diagnosis Analysis), FTA (Fault Tree Analysis) for

Safety relevant functions according ISO 26262

› Design Review

› Change Management

› Lessons Learnt

› R&R (Repetability and reproductibility) Analysis

Automotive product quality development Supporting Tools

January 28, 2014


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for your attention! Thank you

January 28, 2014
