Hardware Development

Automotive ECU

An Electronic Control Unit (ECU) is any embedded system in automotive electronics that controls one or more of the electrical systems or subsystems in a vehicle.

We are working on Automotive ECU which are mostly concerned with safety of vehicle and human life.
Brake , Steering , Suspension , ADAS , Electric vehicle ECUs are our major development areas.

We perform complete hardware development lifecycle which includes designing an ECU from a conceptual idea to mass production following ISO26262 functional safety process.

We have a complete team of expert engineers involved in concept design, circuit development, PCB development , Housing development , EMC & thermal analysis as well.

ECU Hardware Development

ECU HW development mainly focuses on Circuit development cycle. It starts from conceptualizing of hardware architecture to testing of DV samples to supporting in vehicle testing adhering to functional safety standards ISO26262.

Main Work Area
ECU Circuit / Testing
  • Hardware Architecture
  • Circuit design & BOM
  • ECU level simulation
  • Proto Sample development
  • Hardware Unit & Integration test
Hardware Functional Safety
  • HARA – Analyze ASIL level
  • FMEA - Analyze safety hazards-RPN
  • FMEDA - Hardware architecture metrics
  • FTA - Random Hardware Failures-PMHF
Hardware Validation
  • Create virtual car environment for ECU
  • Automate test cases for ECU Validation
  • Semiconductor Validation
Upcoming Technology & Innovations
EV
  • Working with MDK on EV vehicle ECU design for Fully & Hybrid Electric vehicles
  • System simulation of EV vehicle
  • Development of eRicksaw & eBike ECU for Indian market

PCB Design

PCB Design

PCB Team co works with Global Mando subsidiaries (MDK, MSI, MRE) to make best in class PCBs. PCB is designed considering all Electrical (DFE, EMC/EMI, ESD), Mechanical (PCB 3D Model, Housing Interference), Thermal and Fabrication/Assembly (DFM, DFA) requirements.

Main Work Area
PCB Design
  • Mass Product Design based on Automotive Environments
  • Compliance to IPC and Automotive standards
  • Global Mando PCB Specs
  • PCB 3D step modeling
  • Rigid-Flex, Ceramic, Embedded PCB Design
Library Database Management
  • Electronic parts creation and update
  • Centralized Database Management
  • Parts Mechanical and Electrical information
PCB Verification
  • DFM Verification
  • DFE Verification
  • CAM Verification
  • PCB trace current carrying capacity calculation
PCB Fabrication
  • Assembly Data
  • CAM Data
  • Stencil Data
  • ICT JIG Data
Main Products
Mass Product PCB Design
  • Brakes (MoCi, ESCi, IDB)
  • Steering (CEPS, REPS)
  • Suspension (SDC, SCU)
  • ADAS (DCU, SPAS, PCU)
Advanced PCB design
  • Gate Diver, Logic Card
  • Integrated Deisgn (MoC+SDC, MOC+ABS)
  • Low Cost Design ( MoCi Next Generation, RCU)

EMC Analysis

EMC Simulation

The increase in electronics activity has posed potential electromagnetic interference (EMI) hazards for sensitive electrical and electronics equipment used in many areas.

EMI/EMC analysis in the development process of the product / system in order to identify critical issues and fix them in the beginning. EMI/EMC includes project execution experience of building concepts of EMI/EMC, EMI source, Automotive Standards (CISPER25), Control Techniques, Measurements and providing competent EMI/EMC design solutions, optimization early in the development cycle.

Main Work Area
  • Signal Integrity Analysis (SI Analysis)
  • Power Integrity Analysis (PI Analysis)
  • Conducted Emission Analysis
  • Radiated Emission Analysis
  • Parasitic RLGC Extraction
Upcoming Technology & Innovation
  • Conducted Immunity/Susceptibility Analysis
  • Radiated Immunity/Susceptibility Analysis

Thermal Analysis

Thermal Simulation

Thermal Analysis team is responsible for Thermal, CFD, Thermal Stress analysis of ECU and Motor design. Aim is to improve heat dissipation performance and reduce the risk of failure due to temperature rise.

Main Work Area
  • Thermal analysis of ECUs at component level, PCB level and system level.
  • CFD analysis to check fluid flow
  • Thermal-stress simulation to check failure of the system due to stress generated by temperature
Upcoming Technology & Innovation
  • Electro-thermal simulation
  • Thermo-mechanical simulation

Housing Design

ECU Housing

Housing design team is responsible for design of ECUs mechanical casing and complete Motor design. Aim is to optimize design to reduce weight and cost of the product as per the market trend.

Main Work Area
  • 3D architecture of ECU housing and Motor parts such as rotor , stator, magnet, shaft, core, housing , terminal etc
  • Detailed drawings to describes each part structure for the manufacturing
  • Selection of the material based on the application
  • Design validation based on the manufacturing process and material
Upcoming Technology & Innovation
  • Motor coil designing
  • ECU vibration analysis
  • Permanent magnet size and shape calculations

Achievements

Achievements
Participated in Halla Future day in 2019 & 2020
  • Black Box (2019) : Got 4th position award at Global Mando
  • V2V Communication System : Appreciated by Global Mando Selection Team
Developed Simulators for ECU testing
  • SDC Simulator
  • MHI Simulator
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