Automotive Research Association of India
Research Institute of the Automotive Industry with the Ministry of Heavy Industries & Public Enterprises, Govt. of India
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R&D Services » Electronics

With the advancement of technology, role of electronics in automobiles is on the rise. Electronic modules are used today to perform most of the control functions in the typical automobile that 25 years ago were performed by mechanical mechanisms. Considering growing importance of electronics in automobiles, Automotive Electronics Department (AED) of ARAI is engaged in

Development of embedded electronics systems for automotive applications
ARAI offers a unique combination of expertise in automotive & embedded electronics domains. End -to end solutions in automotive embedded electronic systems are provided based on expertise and competency generated over the years making us the preferred partner in development of automotive embedded electronics systems.
Services:  
  Hardware, Firmware design architecture for engine controls, safety, in vehicle network
  Proof of Concept (PoC) Development
  EMI EMC analysis and solution design
Key Products:  
  In-vehicle Duty Cycle and Operation Pattern Recorder
  Conversion of legacy sensors data to CAN messages
Key Projects:  
  Development of Two Wheeler Fuel Injection ECU
  On Board Diagnostics for Gasoline and Diesel Engines
  Frontal Collision Warning System
  ECU development for dual fuel application
Model Based Design and Rapid Prototyping tools for ECU Control Strategies development
MBD (Model Based Design) and RPT (Rapid Prototyping) approach for ECU (Electronic Control Unit) development, optimization and validation has become De facto for advanced and complex automotive control systems. ARAI has recently established a complete tool chain for the same. The setup at ARAI is a heterogeneous mixtu re of best tools available in the market which is brought to close coordination with the domain expertise and software skill, puts forward the unique combination required for automotive solutions viz. Powertrain, Chassis, Diagnostics, Body Control, Infotainment etc.
Matlab/Simulink, Stateflow & associated tool boxes: for Control algorithm formulation.
Prototyping ECUs
dSPACE Micro Autobox and Rapid Pro unit
Pi Shurlok G850 OpenECU
Pi Shurlok M250 OpenECU with S070
Real Time Simulator for HIL
Automation Test Software
ECU experiment development Software(Control Desk)
Plant Models
IPG Carmaker
enDYNA CRTD
enDYNA Fuel Direct Injection package
ETAS INCA for ECU calibration
OBD Scanner
Key projects executed are
Integrated Safety System (ABS, TCS, YSC, RSC and Active Seat Belts) for an Indian Vehicle
Development of GDI control strategies
ECU Verification & Validation facility
Electronic Control Unit (ECU) is becoming integral part of modern vehicles. Vehicles contain number of ECUs like engine, transmission, safety, driver assistance, body control, infotainment, etc. Overall complexity and dependency on software have increased over the period. Hence it is extremely important to test and validate the performance of the ECU before deploying it in a ctual working environment.
Citing the complexities, time, efforts and resources involved in the conventional ECU validation process, Automotive Electronics Department (AED) of ARAI has started a new service offering and established dedicated facility for ECU Verification & Validation (V&V) in simulated laboratory environment i.e.; in Software-In-Loop (SIL), Model-In-Loop (MIL),Rig In Loop (RIL), Hardware-InLoop (HIL).
Benefits of the V & V System over Conventional ECU testing:
Reduction in Development Time
Early Problem Detection
Easy to back trace problems
Low Defect Fixing Cost
Reduced Testing efforts in DYNO/Actual vehicle test environment.
Various tests can be performed according to the product requirements. Tests can be broadly classified as below:
Functional Validation
White Box testing with functional knowledge
Black Box testing without functional knowledge
Diagnostic Testing
Orthogonal Array (OA) Testing (Abusive Testing)
Voltage Profiling
Acceptance Test
Boundary Condition Test
Unit Level Test
System level MIL
Real Time Simulator for HIL
Our success stories include
OBD II Evaluation for CRDI with EGR ECU
OBD II evaluation for CRDI SCR ECU
In vehicle OBD Verification and validation for an Indian Sports Car
ECU Calibration services on HIL and in vehicle
Modern vehicles contain number of ECUs right from engine, transmission, safety, driver assistance, body control, infotainment, etc. ECU calibration is one of the most critical parts of the entire ECU development process and also consumes a lot of time, efforts and resources.
Coping with calibration tasks generally requires a lot of human and material resources. A correspondingly large number of calibration and measurement systems are in use, involving high costs for acquisition, maintenanc e, training, and support.

By using the Real Time Simulators, we can save a considerable amount of time and resources involved in the calibration tasks. Availability of RT Simulator and off the shelf plant models make this task of calibrating ECU's easier in the lab than on the vehicle. The actual components like injectors, spark plugs, throttle body etc. can be used in the lab to make the calibration setup closer to the real vehicle. Standard calibration tool like ETAS INCA is available to carry out this activity.

Chassis dynamometer facility with full flow dilution system & emission analyzer and AC engine dynamometer facility are available to complement the above tool chain wherein, the control strategies and calibration can be verified and validated on the actual vehicle/engine. Also offered are services and support with a host of instrumentation for vehicle / engine such as various pressure / temperature / vibration sensors, lambda meters, fuel consumption meter, high speed data acquisition system, robot drivers for consistent and repeatable trials, etc.

Evaluation of Auto Electronic Systems
AED has full-fledged ‘under one roof’ test facility for evaluation of automotive electronic systems for EMI/EMC, environmental conditions, vibration and thermal shock.






Development of Automated Vehicle / Engine Test Instrumentation Systems
AED has been working on the development of test instrumentation and automation systems required for automotive engine and vehicle testing. AED has following standard products and have been offered to the automotive industry

  CDCS: Chassis Dynamometer Control System   Digital Dyno Controller
  Saarathi: Drivers’ Aid System   GDACS: Generator Data Acquisition And Control System
  EDACS: Engine Data Acquisition And Control System    

AED has also developed customised solutions for the special test instrumentation such as SHED Automation Controller, CVS Controller, Test Cell Automation System (TCAS), Image Analysis applications in automotive testing and High Speed Vehicle Data Acquisition Systems.

AED can offer any customised solution for Test Instrumentation, PC based data acquisition and Control and test automation for automotive testing and evaluation.
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Chassis Dynamometer Control System (CDCS)
AED offers a complete solution of chassis dynamometer for vehicle evaluation. It is a moving road in the lab. The system meets the national and international regulatory requirements. Typical features include :

Dedicated controller with real time operating system and deterministic performance.

Master-Slave configuration gives very good real time control and powerful user interface.

Total Electrical Inertia Simulation

Database Connectivity : Easy storage, retrieval and analysis of various test and calibration data

Remote Diagnostic Facility, Host Computer interface.

Saarathi (Driver’s Aid System)
A PC based solution to display, edit, configure and run drive cycles. Features: Display of quantitative driving performance, User selectable cycle scroll either horizontal or vertical, Split of driving cycle as warm-up and testing duration, Selection of driving cycle from Standard Driving Cycles or User defined driving cycles, Import from Excel, Remote operation with the help of handheld pendent, Host Computer connectivity on TCP/IP.


E-DACSTM (Engine Data Acquisition & Control System)
Modern engine development programs requires engine test system with monitoring and storage of large number of parameters, control of engine and dynamometer through a pre-determined test sequence, post processing of the acquired data and simultaneously acquisition and recording of the parameters which are transient in nature like combustion pressure. All of the above capabilities are integrated in E-DACSTM.TM


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  Windows Based Software For Data Acquisition And Control
  Open architecture
 
Interface with standard dyno instrumentation- Dynamometers, throttle controllers, smoke meters, blow-by meters, exhaust back pressure controllers, fuel and coolant conditioners, emission equipment including CVS, particulate samplers, and gas analysers
  Wide library of different make equipment
  Real time architecture for control, data acquisition.
  Scalable data acquisition from 16 channel to 512 channel
  LAN based connectivity with data acquisition system
  Automatic/ Semi-automatic/ Manual Modes
  Test sequence program editor.
  Runtime display of acquired and calculated parameters.
  Graphical display of critical engine parameters such as speed, load, lub oil temperature etc.
  Special Report generation utility

DIGITAL DYNAMOMETER CONTROLLER
  Torque control - capability to run steady state endurance cycles and Transient cycles.
 
Possibility of manual mode operation (with potentiometer) with indication of speed, torque, along with speed and torque sensor amplifiers, Power and dyno related alarms etc.
  Modes of operation
  Speed by dyno / % throttle position
  Torque by dyno / % throttle position
  Speed by dyno / torque by throttle
  Torque by dyno / speed by throttle
  % load (current) position / % throttle position
  Bump less transfer of modes
  Digital multipoint calibration for all inputs, outputs for all modes.
  Software PID control for all closed loop control modes, PID adjustable and password protected.
 
4½ digit, non re-settable hour counter to be synchronised with RPM. Provision of digital output on activation of Hour Counter.
  Torque analog output and rpm pulse output
  Remote Mode of Operation for HOST control
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Test Cell Automation System (TCAS) :
Test Cell Automation System (TCAS) is a system comprising of all required software and hardware for the automation of Emission test cell equipment. TCAS provides the single console control of the all emission measurement equipment namely, Chassis Dynamometer, Gas Analyzer, CVS, Drivers’ Aid System. Additionally, following equipment can also be integrated and configured to work under TCAS : Idle Gas Measurement Analyzer, Smoke Meter, Data Acquisition Box , Weather Station, GSM Modem, RPM Meter.

TCAS controls above equipment during the emission test according to the specified test procedure. All major international and Indian test procedures are in- built in TCAS. It also provides the facility to define customized test procedures.

Features
  Enables data sampling of all the equipment required for emission certification / development testing of vehicles.
  Controls all the emission relevant subsystems through single console.
  Performs the test according to the given regulations and status monitoring of the equipment for deviation from regulations.
  Provides WINDOWS based Graphical User Interface for easy operation and Configuration.
  Provides comfortable entry of test data, vehicle data and test parameters, supported by a utility to retrieve stored data.
  Provides Test Editor Window to define test phases, cycles and procedures with parallel operation of the sub- systems.
  Enables to define different configuration settings of the sub- systems to adapt to the variety of test procedures and R&D tests.
  Online display of the measured and evaluated data. Free selection for display of traces of all selected attributes. Selectable color and thickness for each selected trace.
  All relevant data are time-stamped for synchronization purposes.
  Automated data storage at test end and assignment of a test number.
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