Qualità e Sicurezza A cura di Aicq e Anfia. Torino, Lingotto Fiere 18 aprile 2013

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1 Testimonianze sullo stato dell arte nei settori veicolistici: Autoveicoli Motocicli Macchine Operatrici L'esperienza BREMBO nell'applicazione dell'iso26262 Ing. Luca Cappelletti Direttore Mechatronic Group - BREMBO S.p.A.

2 Experience how functional safety is implemented 2

3 Agenda Presentation of Brembo Mechatronic group Adopted Processes Pilot project

4 "Strictly Confidential. Brembo S.p.A. reserves all rights of use and disposal, under the protection of the law, also in connection with I.P.R., as well as copying and passing on to third parties" Presentation of BREMBO

5 Presentation of BREMBO A world Leader in the design and manufacturing of high performance braking systems and components. Full control of the industrial process, from casting to assembly, is a guarantee of product quality. At Brembo, innovation involves new technologies and new materials. Functional design in addition to performance and comfort.

6 Customer PASSENGER CARS Brembo develops and manufactures braking system components and modules, for customers worldwide. Products: brake discs, high-performance brake calipers, wheel-end modules, flywheels. MOTORCYCLES Brembo develops and manufactures braking systems for motorcycles, scooters, and ATV. Products: brake discs, brake calipers, master cylinders, assembled and pre-bled brake modules and wheels.

7 Research and Development Center Brembo Research and Development is clustered in the Research and Development Centre, inside of the Scientific and Technological Park Kilometro Rosso.

8 "Strictly Confidential. Brembo S.p.A. reserves all rights of use and disposal, under the protection of the law, also in connection with I.P.R., as well as copying and passing on to third parties" Mechatronic Group

9 Mechatronic group Starting from July 2009 BREMBO has fixed the following main targets for the development of its safety critical products: 1.Migration from IEC61508 to ISO SW process according also to AUTOMOTIVE SPICE. 3.Design and development of an ECU compliant to ISO and able to support AUTO and VECO applications. The EPB for auto applications (SOP in 2013) has been selected as pilot project to reach these objectives. Mechatronic Group Mission: Design and develop mechatronic systems according to the reference legislation and standards in order to extend the BREMBO offer to the OEM Evaluate possibility and advantages of entering new markets Study innovative solution to anticipate the trend of the market in order to maintain the TIER 1 position Overview of the group after reorganization. Personnel are organized into the following teams: Safety and process Electric and electronic Mechanical design Testing

10 "Strictly Confidential. Brembo S.p.A. reserves all rights of use and disposal, under the protection of the law, also in connection with I.P.R., as well as copying and passing on to third parties" Adopted Processes

11 Process integration General overview To develop mechatronic systems, the following standards are adopted and used by BREMBO: ISO TS ISO ISO 9126 Automotive-SPICE Certification of Quality System Road vehicles Functional safety SW Quality characteristics Software and System processes A-SPICE ISO TS ISO ISO 9126 BREMBO Mechatronic System Development Process

12 Lifecycle ISO 26262, SPICE process approach The process approach is based on the BREMBO procedure Development of a new project (defined according to ISO TS) where the following standards are re-mapped: ISO AUTOMOTIVE SPICE For each phase the activities requested by the mentioned standards are implemented. To achieve the gates the work products requested by the mentioned standards shall be delivered.

13 "Strictly Confidential. Brembo S.p.A. reserves all rights of use and disposal, under the protection of the law, also in connection with I.P.R., as well as copying and passing on to third parties" Example of Project

14 Electric Parking Brake Strategy BREMBO starts to develop a pilot project with the following characteristics: EPB (master) / ESC (slave) Service + Parking Caliper The ESC system is responsable of vehicle information (wheels speed etc) toward the EPB system. It performs the Dynamic braking depending on EPB request. The ESC system is responsable of the PB functions management

15 Road Map The compliance milestones for ISO are: 2009 PROCESS GAP ANALYSIS CONCEPT PHASE SYSTEM DEVELOPMENT SW DEVELOPMENT HW DEVELOPMENT VALIDATION PROCESS INSTALLATION PROCESS REFINEMENT 2013 PRODUCT VALIDATION ISO COMPLIANCE

16 Concept phase Concept phase: work-products already produced by BREMBO related to the EPB SEooC designed in slave-master configuration and submitted to technical review composite structure L0 - Static View Driv er Cockpit Chassis opt phy phy phy EPB_StatusLamp opt pwr Driver_Request Assembly Assembly B_EPB phy3 phy4 phy5 phy1 TorqueL ForceL phy Disc_L Safety architecture L0: external interfaces dgt Disc_R CAN Tx(DynamicBrakingRequest) Rx(Brake) Rx(ESC_Status) Rx(Wheels_Speed) CAN ESC phy2 EnCU TorqueR ForceR phy Safety goals of the PB item (extracts ) REF Title ASIL Safe state EPB disabled Avoid unwanted ASIL SG1 (no force change dynamic application D allowed) Rx(Accelerator) CAN Rx(Gear) GCU CAN.... Tx(EPB_Status) Rx(Diagnostic) KL15 dgt BCU EDS opt1 CAN opt2 EDS_FaultLamp EDS_StatusLamp MDT CAN SGx Avoid wrong parking notification to the driver ASIL C Status notification not permanently ON (e.g. status lamp not permanently energized) PowerSupply Power pwr

17 System development composite structure L1 - Static View B_EPB PBCU PBAU_L pwr dgt Power KL15 pwr1 dgt1 pwr3 PBAU_L_Power pwr phy TorqueL ForceL phy1 CAN Tx(DynamicBrakingRequest) Rx(Brake) Rx(ESC_Status) Rx(Wheels_Speed) Rx(Accelerator) Rx(Gear) Tx(EPB_Status) Rx(Diagnostic) DCU_Position CAN dgt4 pwr2 pwr4 dgt2 PBAU_R_Power pwr PBAU_R phy TorqueR ForceR phy2 Safety architecture L1: system architecture. Down to system level L3 DCU_Power_12V DCU (including Status Lamp) DCU_StatusLamp pwr dgt1 dgt2 phy opt Driver_Request EPB_StatusLamp phy3 opt Signal interfaces EPB Evaluate DCU status Read data via CAN and calculate the vehicle speed Decide all functional strategies Apply and release the static PB force Send via CAN to ESC the dynamic/emergency braking request ESC Provide via CAN the vehicle dynamic data and other relevant signals: wheels speed, service brake pedal, Provide via CAN to EPB its internal state Perform the emergency/dynamic braking via hydraulic service brake system under EPB command

18 Process overview Requirements Developed in DOORS. Hierarchical structure implemented to identify requirements for each design level Design Developed in SysML. Hierarchical structure implemented to develop the system design down to the HW and SW design. Allocation Requirements allocated to each element of design, HW and SW requirements included. SCOPE Set up a method to evaluate the impacts of the various solutions requested by the customers.

19 "Strictly Confidential. Brembo S.p.A. reserves all rights of use and disposal, under the protection of the law, also in connection with I.P.R., as well as copying and passing on to third parties" THANKS!