Measurement, ECU Calibration, and Diagnostics

DevelopmentSolutions for Automotive Embedded Systems

Contents

1.

Introduction

2.

Applications

2.1 Calibrating Automotive Electronic Systems

3.

4.

2.2 On- and Offboard D

iagnostics

10

2.3 Vehicle Testing

11

2.4 Process Integration

13

2.5 Frontloading

13

2.6 Automation

14

INCA Product Family

17

3.1 Measurement and ECU C

alibration

18

3.2 Diagnostics

18

3.3 Measure Data Analysis

21

3.4 Simulation and Prototyping

21

3.5 Measurement and Calibration at the

Test Bench

22

3.6 Open Interfaces

24

Hardware Products

27

4.1 Universal ETK/XETK ECU Interfaces

28

4.2 ECU and Bus Interface M

odules

32

4.3 Measurement Modules

37

4.4 Unattended Logging of INCA Data

40

5. Application Engineering Services

43

1.

Introduction

ETAS provides development tools for measurement,

calibration, and diagnostic (MCD) to automakers (OEMs)
and suppliers worldwide. ETAS hardware and software
products form an integral part of the development process, assisting engineers in everything from developing
application software for electronic control units (ECUs) to
the integration of automotive electronic systems in the
vehicle.
This brochure provides an overview of ETAS MCD products
and their applications. Engineers use INCA and ETAS ECU
and bus interfaces along with measurement modules to
calibrate, validate, and diagnose automotive electronic
systems and to acquire reliable data from those systems
and the vehicle environment.
ETAS tools address the requirements of development and
testing applications in the laboratory, at the test bench,
and on the road. ETAS products and services encompass a
wide array of features and benefits:
One-stop shopping for full-system solutions with local
expert support
Comprehensive software tools for advanced applications
Compact-sized, rugged hardware designed for automotive environments
Scalable and flexible hardware configurations
Support of a wide variety of ECU interfaces
Acquisition of accurate measurement data
Open interfaces compliant with automotive standards
ETAS continuously seeks customer feedback and investigates the latest technology trends in order to provide the
most innovative products for the development and testing
departments of the automotive and commercial vehicle
industries. ETAS participates actively in the standardization committees of ASAM, AUTOSAR, FlexRay, JasPar, LIN,
Nexus, SAE, and ISO.

Figure 1:
Requirements for measurement, ECU calibration and diagnostic (MCD) tools.

Figure 2:
Chassis applications driver assistance s ystems and vehicle dynamics management.

Figure 3:
Powertrain applications conventional and alternative systems.

2.

Applications

Electrical and electronic systems comprise a substantial

segment of the feature and function set of modern
automobiles and trucks. The cost efficient implementation
of intelligent functions, both within and beyond the
domains of powertrain, chassis, and body, is accomplished
with the aid of electrics, electronics, and software.
As a function of the rising demands on our automobiles
drivability, convenience, safety, and environmental
compatibility, the number and complexity of electronically
implemented vehicle functions are increasing steadily.
Todays midsize cars being equipped with engine and
transmission controls, electronic brakes, occupant safety,
as well as driver assistant and infotainment systems,
feature some 40 electronic control units (ECUs). Modern
engine control modules process up to 250 MIPS (million
instructions per second); these may contain upwards of
20,000 function parameters. The same magnitude applies
to the volume of code onboard the ECU, the logical core
of all control and diagnostic functions.
Modern automotive systems are interconnected by onboard data buses. The engine management is connected
to the electronic brake. Adaptive cruise control makes
use of position data provided by the navigation system.
Hybrid propulsion has to manage engine, transmission,
brakes, battery, and electric motor/generator in a
combined control approach. New vehicle bus systems such
as LIN and FlexRay have been introduced to provide solutions for low cost or high performance requirements.
INCA offers connectivity to all relevant bus systems. It
provides for calibrating and diagnosing multiple ECUs
while monitoring bus communication and acquiring
measurement signals from the vehicle environment. INCA
supports all standard ECU description formats as well as
measurement, calibration, and diagnostic protocols.

2.1 Calibrating Automotive Electronic Systems

ECU software is parameterized in such a manner that the

behavior of control and diagnostic functions can be easily
adapted to a variety of system variants or vehicle models
by calibrating or modifying the characteristic values of
function algorithms, without the need to change calculation routines. Using calibration tools, characteristic values
can be tuned on-the-fly while at the same time acquiring
signals from ECUs, vehicle buses, and measuring devices.
Vehicle performance is partially determined by the quality
of calibration data. Calibration, i.e., the finding of an
optimized set of ECU parameters for a new vehicle, has
become a crucial element in the development of new
engines and vehicles. It accompanies the development
process from the first prototypes until after SOP.
A main challenge for calibrating complex ECUs are
contrary requirements, such as NOx versus CO2 reduction.
In addition, calibrations of electronic systems have to
be done for a number of different vehicles or model
variants which are sold in the different markets. Not
only do ten thousands of calibration parameters have to
be considered, but also numerous interactions between
different software functions and ECUs must be taken into
account. Calibration tasks are normally conducted in a
work-split between OEM, ECU-suppliers and engineering
companies. The tasks are iterated on different levels of
detail throughout the development process.

Typical engine calibration tasks for example are:

Optimization of base engine parameters such as injection, ignition, or valve timing with respect to engine
outputs such as power, torque, fuel consumption, and
emission under stationary or transient, and cold or hot
temperature conditions.
Parameterization of algorithms which derive key engine values such as torque, air and fuel mass, temperatures, or raw emissions by calculations.
Optimization of idle-control and driveability to
achieve the best trade-off between sportiness and
comfort.
Parameterization of correlated safety relevant functions such as vehicle dynamics control.
Refinement and validation of calibrations under realistic and rough environmental conditions during test
trips.
To manage complex optimization tasks, calibrators require
solutions that combine human expertise with best practice
optimization methods and easy data handling. INCA
offers sophisticated calibration functions and data management capabilities. In addition, INCA provides interfaces
to enterprise data backbones for automating calibration
procedures. Interfaces enable the integration of INCA
functionality into customer specific solutions.

Figure 4:
Progress of memory size (in MByte), calibration parameters (number), and calculation power (in mega instructions per second / MIPS) bandwidth of engine
control units over the period since 1995.

2.2 On- and Offboard

Diagnostics
The need for sophisticated ECU diagnostics onboard
the vehicle is mainly driven by legislative standards for
onboard monitoring of emission relevant systems such as
OBD and EOBD regulations. Offboard in the service shop,
correct and efficient identification of faulty components is
essential.
The ODX Open Diagnostic Data Exchange Format declares
onboard diagnostic functions and protocols in a standardized manner. The XML-based data description format
enables vehicle manufacturers and their suppliers to maintain all data of the vehicle life cycle, i.e., development,
production, and service data, in a uniform way. ODX was
specified by ASAM and is published as ISO 22901-1 international standard. More and more car manufactures and
suppliers support ODX with their diagnostic development
tool chain.
Comprehensive vehicle diagnostics requires close cooperation between ECU and service diagnostics development.
When offboard diagnostic functions are developed in
parallel to the ECU software, they can be tested at an
early stage of development.
INCA facilitates ECU diagnostics and flash programming
compliant to the OBD and ODX standards. Being able to
execute software functions and sequences of service testers, INCA provides for the validation of service diagnostics
before service tester hardware is available.

10

2.3 Vehicle Testing

Laboratory testing of automotive systems is followed by

in-vehicle tests. Road testing shifts from initial trials on
dedicated proving grounds to public roadways. Standard
drive cycles, e.g., stop-and-go in city traffic, are conducted
as well as high-speed runs or tests under various road
conditions. In many cases, to verify performance under
extreme conditions of temperature and altitude, vehicles
are subjected to driving tests in Arctic regions, desert
areas or high mountain ranges.
Calibration engineers adjust and optimize electronic
systems onboard the vehicle with regard to driving characteristics. In addition, thresholds of diagnostic functions are
verified against environmental parameters.
Vehicle testing has to be very efficient, since development
cycles become shorter and the number of test vehicles
is becoming more and more limited. Data has to be
acquired throughout the entire vehicle trial to maximize
test coverage.
Drive recorders are an important part of test engineers
tool sets. For validation tasks performed within the
development phase, ETAS offers drive recorders that
provide for unattended operation of INCA functions. They
replace the laptop with the INCA software and utilize
ETAS measurement hardware, ECU and bus interfaces, and
INCA experiment configurations. Vast measurement files
can be recorded and analyzed by use of the MDA Measure
Data Analyzer.

11

12

2.4 Process Integration

2.5 Frontloading

Today, the development of complex electronic systems

and their attendant ECU software is an effort which is
often shared by globally acting workgroups coming from
different domains and belonging to different companies.
The highly iterative calibration and validation tasks are
performed in various phases of ECU software, system,
and vehicle development. They involve calibration and
test engineers as well as function developers, software
engineers, diagnostic experts, and documentation teams.

Every package of calibration work which can be frontloaded from the vehicle to earlier development phases
reduces the need for costly test vehicles, saves valuable
engineering resources and helps to locate errors and gaps
in the design of vehicle functions at a point in time where
the effort for correction is still low. The use of advanced
simulation and prototyping technologies facilitates
performing calibration and validation work in the lab, at
test benches, or Hardware-in-the-Loop (HiL) systems, or in
virtual environments on the PC.

Calibrators require comprehensive information on ECU

functions. In addition to displaying control parameter and
variable values, a calibration tool must be able to handle
graphical representation of software control models,
software engineering documentation, calibration history,
bus protocol information and much more. INCA provides
all the necessary information at one glance.

INCA provides dedicated add-ons for the calibration of

ECU function prototypes or simulation models in real or
virtual environments. For ECU testing with a HiL system,
e.g., in a drive simulation, INCA can be used as a measurement and calibration server.

For integration with customer processes, existing data

backbones and tool environments, INCA provides open
interfaces and off-the-shelf add-ons to the basic product.
It offers standard interfaces to test benches and external
applications such as MATLAB. In addition, INCA comprises
a COM-API interface for programming customized applications.
Calibration artifacts are often stored in dedicated
enterprise data management systems. INCA integrates
with all established systems such as Vector eASEE.cdm,
AVL CRETA, or IAV CalGuide. Calibration projects,
work results and progress, as well as access rights can be
exchanged between INCA and those systems.
Calibration and validation tasks are subject to increasing
pressure on resources in terms of prototype ECUs, test
bench sessions, and test vehicles. To meet cost, time, and
quality objectives, development processes constantly demand efficiency improvements. This leads to the general
trend of automation and frontloading.

13

2.6 Automation

Empirical calibration and validation steps are replaced

by predefined procedures which can be fully or partially
automated. Automated procedures can be performed in
much shorter time: Error prone tasks can be done more
dependably and even complex and critical tasks become
reproducible. Mathematical optimization algorithms and
environment models support effective automation.
Automation of calibration and validation tasks may
comprise single operations, e.g., ramping up parameter
values, or full tests or calibration runs without any human
interaction. In the vehicle, calibration procedures which
are repeated many times, e.g., when adjusting gear shifts,
are often automated.
At test benches, automation systems control experiments
and perform much of the calibration work. In steady state
experiments, measurement and calibration tasks are not
performed until the behavior of the unit under test, e.g.,
the engine, at a certain working point is stationary. Dynamic transient state experiments are more realistic and
thus improve the quality of measurement and calibration
data. In addition, they minimize automation cycle times.
To perform dynamic experiments, rapid measurement
and calibration methods are required. The same is true
whenever control functions such as knock protection are
conducted by the test bench instead of the ECU. In this
case, a real time interface between the test bench and the
ECU is requested.
ETAS open and flexible MCD solutions support the
automation of measurement and calibration tasks. INCA
supports ASAM as well as real time Ethernet protocols,
providing remote access for test bench automation
systems. In addition, application programming interfaces
are provided.

14

Figure 5:
Forecast: calibration efforts will be shifted from the vehicle to the test bench and to the PC.

Figure 6:
INCA provides open interfaces for integration with existing processes, data backbones, and tool environments.

15

16

3.

INCA Product Family

With INCA, ETAS offers a flexible family of software

products for calibration, diagnostics, and validation of automotive electronic systems. INCA is successfully employed
in more than 20,000 installations worldwide. It comprises
all functions required by development, calibration, and
test engineers to validate, adapt, and debug ECU application software. INCA is easy to use and offers user-oriented
interfaces available in English, German, French, Chinese,
or Japanese.
INCA is used throughout the development process
from the initial calibration of a function model, to the
pre-calibration of an ECU at the test bench, to the final
optimization in the vehicle. It is deployed at the desk, in
the lab, at the test bench, and in the vehicle. Applications
range from PC simulations to vehicle instrumentation and
from offline management of calibration data to measurement analysis.
INCA supports the full line of ETAS compact hardware
modules and the powerful ETK/XETK ECU interfaces in
measurement, prototyping, calibration, and diagnostic
applications. For effortless integration into different
environments, INCA offers a wide range of open and
standardized interfaces.

17

3.1 Measurement and ECU

Calibration

3.2 Diagnostics

INCA facilitates the adjustment of function parameters,

maps, and tables either offline or during ECU runtime.
In the course of this, the tool manages the ECUs volatile
and non-volatile data memory and resolves parameter
dependencies. Powerful editors display scalars, curves,
or maps as tables or graphs in physical or hexadecimal
format. Calibration scenarios embrace multiple parameter
values of specific functions and ease the comparison of
different settings.

ECU diagnostics is added to the measurement and calibration functions by the ODX-LINK complement to the INCA
basic product.

For offline management of calibration data, INCA offers

sophisticated functions for listing, comparing and merging
datasets. In addition, INCA supports processing of meta
data describing the history and maturity of a parameter or
function calibration.
In parallel to calibration, INCA provides for the acquisition
of data from the ECU and vehicle busses such as CAN, LIN,
Ethernet, and FlexRay. In addition, INCA measures signals
from sensors and the vehicle environment. Quantities
derived from measurements and calibration variables can
be calculated and displayed online. Data recording may be
started and stopped by sophisticated trigger conditions.
Parallel recording of data related to different trigger conditions is possible. Data records comprise measured and
calculated signals, calibration parameters, trigger options,
user comments, as well as ECU memory dumps.

18

INCA/ODX-LINK acquires calibration and diagnostics related signals in parallel. Both types of signals can be used
for triggering and calculation of derived signals in the
same manner. All data are recorded in one measurement
file and displayed in the same views. A single ECU and bus
interface module can provide connections for both, ECU
diagnostics and calibration.
ODX-LINK integrates scan tool functions based on diagnostic services required by OBD emission regulations. Being based on the services defined by ISO 15031-5 and SAE
J1979 only, the easy to use OBD scan tool visualizes fault
memory entries, status information of monitoring functions, vehicle information, in-use monitor performance
ratios, and environmental data known as freeze frames.
Beyond OBD, ODX-LINK facilitates full diagnostics of
ECUs compliant to the ODX standard. In addition, INCA
can emulate a service tester and execute troubleshooting
functions. In this way, service diagnostics can be validated
long before service tester hardware is available. Also
including a remote-operable ODX-FLASH tool, INCA/ODXLINK provides a complete solution for validating ODXbased vehicle diagnostics and ECU reprogramming.

Figure 7:
With ODX-LINK, INCA provides a complete solution for the validation of
vehicle diagnostics and flash programming.

19

Figure 8:
From electronic control units to experimental systems to virtual
environments on the PC, INCA connects to all kind of targets employed
for simulation, protoyping, test, and production.

20

3.3 Measure Data Analysis

3.4 Simulation and Prototyping

In the ECU development process, measurement data that

relate to different variants of calibration parameter values
have to be compared. The MDA measure data analyzer
is used to visualize, post process, analyze, and document
measurements. It provides for evaluating the correlation
of diagnostic data with signals from the ECU, sensors and
vehicle busses. By use of predefined configurations, measurements can be displayed in a uniform manner. By using
the same views and settings for the same signals independent of the individual record, similar measurements can
be easily checked against each other. MDA print layouts
are adaptable to corporate design rules and provide for a
professional documentation of the measurement results.

The comprehensive measurement and calibration

capabilities of INCA can be most beneficially employed in
PC simulation and prototyping applications. Simulating
the behavior of new software functions in a modeling
environment on the PC is an established development
method. Prototypes are used to validate new functions in
a real environment.

In the course of simulating, prototyping, or testing

functions, measurement data often serve as stimuli. MDA
is used to select and prepare stimuli signals from raw
measurement data which was recorded at the test bench
or in the vehicle. MDA is capable to process large amounts
of measurement data. It supports the MDF file format, an
ASAM standard which is commonly used by development
and test tools.

Function prototypes can be implemented on different

targets. As required, they may be executed on an ECU,
an experimental system, or a PC. Regardless of the
simulation or prototyping environment that is employed,
INCA provides add-ons that establish measurement and
calibration access. INCA-SCX connects to generic simulation environments on the PC using the XCP protocol over
TCP/IP connection. INCA-SIP links INCA with Simulink.
ETAS INTECRIO facilitates integration of generic C code,
Simulink and ASCET models within one prototype. INCAEIP provides full access to INTECRIO prototypes running
on the PC and to INTECRIO or pure ASCET prototypes
implemented on an experimental system. By using the
same INCA tool at each step, calibration values can be
easily refined.

21

3.5 Measurement and Calibration at the Test Bench

For integration with test bench automation systems, INCA
supports the established ASAM interfaces, i.e., the ASAP3
protocol and the ASAM MCD-3 MC object model. The
calibration cycle times that can be realized with these
standard interfaces are well suited for steady state experiments.
Rapid measurement and calibration methods are supported by the INCA-MCE Measurement and Calibration
Embedded add-on to INCA. By providing real time
connection of the test bench automation tool to the ECU,
INCA-MCE provides for outstanding measurement and
calibration performance.
INCA-MCE runs on the ES910 module serving as real
time ECU interface. Either the standard EtherCAT or the
application specific iLinkRT Ethernet real time protocol
is employed to connect ES910 with the test bench. Using
these protocols, the automation tool and INCA-MCE
exchange measurement and calibration parameters as
physical values addressed by name. To communicate with
the ECU, INCA-MCE transforms all data into the appropriate binary values and memory addresses.

22

Figure 9:
INCA-MCE connects the ECU with test bench automation systems in real time.

23

3.6 Open Interfaces

In addition to automation system interfaces, the tools of

the INCA product family provide a wide range of open
and standardized interfaces for configuration, data
exchange, documentation, automation, and integration
with customer applications.
ECU access is configured by using description files in
A2L and ODX format as defined by the ASAM MCD-2
standards. Bus communication on FlexRay, CAN, and LIN is
described in the respective FIBEX, CANdb, or LDF format.
Calibration data are stored in hex formats, whereas several ASCII formats are supported to exchange subsets of
calibration parameters. Measure data is recorded in MDF
files. Being a de-facto standard in automotive testing, the
binary MDF measurement data format is supported by
commonly used data evaluation tools such as MATLAB
and FAMOS.

24

INCA provides parameter listings and the results of

calibration data in XML-format. The configuration of
experiments and connected hardware also can be documented in XML-files. To provide for interactive access of
parameter and function model descriptions within INCA,
an open interface facilitates integration of electronic ECU
documentation in PDF or Windows Help HTML format by
the customer.
For tool integration, INCA offers application programming
interfaces (APIs). The COM-API is based on the Microsoft
COM (Component Object Model) standard. COM-API
facilitates remote control of almost all INCA functions and
provides maximum flexibility. Using INCA-MIP, MATLAB
scripts can be employed to automate or semi-automate
calibration procedures. Manual input provided to the
scripts by INCA-MIP can be combined with numerical
calculation and optimization routines that utilize the rich
MATLAB libraries and toolboxes.

Figure 10:
Open interfaces of the INCA product family.

25

26

4.

Hardware Products

Figure 11:
ETAS hardware products supported by INCA.

27

4.1 Universal ETK/XETK ECU Interfaces

The high standards in terms of performance, safety,

responsiveness, drivability, fuel savings and emissions
met by todays vehicles would not be attainable without
the deployment of ECUs featuring a multitude of sophisticated functions. Powerful measuring and calibration
access constitutes an essential prerequisite for developing
these functions and calibrating the function parameters.
The Ethernet-based ETK and XETK interfaces by ETAS provide direct access to the control variables and parameters
of an ECU via the parallel data and address bus, or via
a serial microcontroller testing or debugging interface.
The ETK/XETK interface is real-time capable. Its dedicated
power supply enables the preparation and initiation of
cold-start testing independently of the ECU. Due to their
extremely compact design, ETKs/XETKs can be accommodated inside the housings of production ECUs. They are
impervious to the temperature extremes and vibrations at
the ECUs location in the vehicle.

In contrast to alternative methods which burden the

ECU program with the task of both data access and data
transfer through a serial interface, an ETK or XETK calls
for very little computing overhead on the part of the ECU.
On engine ECUs, for example, large numbers of measured
values can be acquired easily without impact on ECU
overhead, even in the presence of high engine speeds
with their substantial burden on computing power.
Due to their construction, ETK/XETK development ECUs
do not require an additional serial interface to connect
to the development tool. As a functionally and physically
separate addition to the ECU, ETKs/XETKs facilitate direct
comparison between the behavior of the development
ECU and its production counterpart. Using an ETK/XETK
development ECU, series-production software can be
calibrated with great ease and subsequently verified with
the production ECU without the need to change drivers in
the platform software.

ETK-7.1
XETK-T2.1
XETK-V1.0

ETK-S3.0

28

Figure 12:
Mounting example ETK/XETK-of type VertiCal.

29

Figure 13:
System with multiple XETK-ECUs and an XETK-ECU with multiple
microcontrollers connected to INCA.

Microcontroller Type
(Manufacturer/Family)
Freescale MPC5500

Freescale MPC500
Infineon TriCore
Infineon C166, C167

Interface to ETK/XETK

ETK/XETK Type

Products
ETK-P20.0, ETK-11.0

Data and address bus

Parallel ETK

Data and address bus (standardized VertiCal interface)

Parallel ETK/XETK ETK-V1.0, XETK-V1.0

NEXUS interface (JTAG)

Serial ETK

ETK-S3.0

Data and address bus

Parallel ETK

ETK-P4.0, ETK-P5.0, ETK-P7.0, ETK-P8.1, ETK-P9.0

NEXUS interface

Serial ETK

ETK-S2.0

Data and address bus

Parallel ETK/XETK ETK-T1.1, ETK-T2.1, XETK-T2.1

JTAG interface

Serial ETK

ETK-S4.2, ETK-S1.1C

Data and address bus

Parallel ETK

ETK-7.1

NEC V850

NBD

Serial ETK

ETK-S5.1

Renesas SH

AUD II

Serial ETK

ETK-S6.0

AUD

Serial ETK

ETK-S1.1D

Renesas M32R

JTAG

Serial ETK

ETK-S1.1B

Various third-party
microcontrollers

Data and address bus

Parallel ETK

ETK-7.1, ETK-11.0

Table 1:
Overview of ETK types and interfaces for various microcontrollers and microcontroller families from different manufacturers.

30

Supported microcontrollers
ETAS provides a broad portfolio of ETKs/XETKs for
the commonly used microcontrollers for engine and
transmission ECUs from Freescale, Infineon, Intel, NEC,
Renesas, and STMicroelectronics. ETKs/XETKs are designed
according to customer requirements, e.g., with regard to
memory sizes and mechanical integration with the ECU.
ETK and XETK interfaces provide long-term stability and
downward compatibility. All of the above add up to
a high degree of protection for capital investments in
equipment, tools, and training.
ETK and XETK provide Ethernet interfaces to development tools
ETK and XETK differ in the way the connection between
ECU and host application is set up. ETK-ECUs are
connected to the PC by means of an interface module
which provides for protocol handling. In contrast, XETKs
implement a full functional Ethernet interface on board
to facilitate direct connection to the PC. XETKs utilize the
XCP-on-Ethernet protocol for data transfer. By use of this
standard, they can be integrated easily into existing tool
environments. The XETK is capable of handling up to four
XCP communication channels simultaneously.

This facilitates concurrent access by several PC-based software applications to an XETK-equipped ECU. Several XETK
data lines can be connected to a host computer through a
network module. This option is of interest in the calibration of systems which are either distributed across several
ECUs or implemented by an ECU equipped with several
processors. In such cases, the XETK data of the various
ECUs can be reconciled by means of a hardware-based
time synchronization process.
Full compatibility
ETK and XETK are fully compatible, both in terms of the
interface to the ECU and with regard to the physical
dimensions. Both interfaces are equally supported by INCA
and the INTECRIO and ASCET development tools.
Depending on the use case, XETK and ETK, deliver cost advantages. Deploying an XETK eliminates the expenditure
for the PC interface module, whereas the ETK is the more
cost-effective ECU interface.

31

ES510

4.2 ECU and Bus Interface

Modules
The calibration and test engineers ability to measure
and calibrate an ECUs control and diagnostic parameters
depends on reliable access to the ECU. ETAS provides compact modules that connect the ETK/XETK ECU interface
as well as the K-Line, LIN, CAN and FlexRay serial buses to
the host PC.
When it comes to the acquisition of a large number of
signals, the ETK or XETK is the optimum ECU interface.
To satisfy more moderate performance requirements,
serial calibration protocols like the ASAM-specified CAN
Calibration Protocol (CCP) or its successor, the Universal
Measurement and Calibration Protocol (XCP) - which is
specified for CAN, FlexRay and Ethernet physical layers
- are often implemented on the development ECUs. The
calibration of production ECUs is done on the CAN or
K-Line diagnostic interface via a diagnostic protocol such
as KWP2000. Signal monitoring on the vehicle buses LIN,
CAN and FlexRay complements both testing and calibration applications.
All compact ECU and bus interface modules are integrated within INCA. INCA provides simultaneous support
for the acquisition of ECU and vehicle bus signals via
different modules. Measure data acquired by ES500 or
ES900 modules from the ECU, the CAN or FlexRay bus are
synchronized by INCA with data from sensors and analog
sources. The synchronization enables causal analysis as
well as error tracking. Figure 14 (see page 35) shows the
combined application of measurement and ECU and bus
interface modules by an example.

ES520

ES580

ES585

ES592

32

Hardware Component

ECU and Bus Interfaces

PC Interface

ES510 Network Module

3x Ethernet / XETK

Ethernet

ES511 CAN and LIN Network Module

2x CAN, 2x LIN, 3x Ethernet/XETK

Ethernet

ES512 FlexRay Interface Module

FlexRay (2 channels), 3x Ethernet/XETK

Ethernet

ES520 FlexRay and CAN Interface Module

FlexRay (2 channels), 2x CAN

Ethernet

ES580 PCMCIA CAN and LIN Bus Interface

2x CAN or 2x LIN

PCMCIA-Slot

ES581 USB CAN Bus Interface

1x CAN

USB

ES585 K-Line Interface Centronics

1x K-Line

Parallel Port

ES590 Interface Module

1x ETK, 2x CAN, 1x K-Line

Ethernet

ES591 Interface Module

1x ETK, 2x CAN

Ethernet

ES592 Interface Module

1x ETK, 2x CAN, 2x LIN, 2x Ethernet/XETK

Ethernet

ES595 Interface Module

1x ETK, 1x FlexRay (2 channels), 2x CAN

2x LIN, 1x Ethernet/XETK

Ethernet

ES910 Prototyping and Interface Module

1x ETK, 1x XETK, 2x CAN, 2x LIN

Ethernet

ES920 FlexRay Module

1 FlexRay node with 2 channels

ES910

ES921 CAN Module

2x CAN

ES910

Table 2:
Interfaces supported by the compact ES500 and ES900 modules.

ES920

ES921

ES910

33

ES910 offers high computation power

The compact ES910 module is distinguished by its high
computation power. ES910 lets you easily validate ECU
function prototypes whether designed in MATLAB/
Simulink, ASCET, or coded in C under real-life conditions
in the vehicle. The minimum latency interfaces offer ECU
and bus access to the prototyped functions in real time.
As an option, the ES910 module can be equipped with
ES920 or ES921 modules offering a two-channel FlexRay
node or two additional CAN interfaces. INCA provides for
calibrating the functions running on the ES910 simulation controller.
At the test bench, ES910 supports time-critical calibration
and validation applications by embedding INCA-MCE. To
do this, the ES910 module converts and transfers data in
real time between the test bed control system and the
ECU to facilitate automated calibration with short cycle
times.

34

Figure 14:
Sample setup comprising measurement modules and an ES592/ES595 module acting as
interface to ECUs and the vehicle busses.

35

ES600

ES610

ES611

Hardware Component

Measurement Channels

ES600 Network Module

Connects 6 Ethernet m
odules to one Ethernet link

ES610 A/D Module

16 x Differential voltage

ES611 A/D Module with Sensor Supply

8 x Differential voltage including sensor supply

ES620 Thermo Module

16 x Universal thermocouple inputs

ES630/ES635 Lambda Module

1 x Oxygen sensor input

ES631/ES636 Lambda Module

2 x Oxygen sensor input

ES650 Thermo and A

/DModule

8 x Universal thermocouple inputs, 8 x Differential voltage

Table 3:
ES600 Compact Measurement Modules measurement channels.

ES620

36

ES630/ES631

ES650

4.3 Measurement Modules

ETAS measurement modules are suitable for in-vehicle

and test bench applications where engineers employ
a multitude of sensors to monitor system and vehicle
functions. The modules are used for metering electrical
potentials, to acquire voltages, frequencies, or counter/timer signals from active and passive sensors, and to
monitor temperatures as well as lambda, air-to-fuel or
oxygen content values.
ETAS provides two series of measurement modules
for calibration and testing applications. The compact
ES600 measurement modules are designed for use
in the passenger compartment or in the trunk of a
vehicle. The very small and extra-robust ES400 micro
measurement modules are designed for installation
close to the measurement source. They are well suited
for applications in the exterior parts of a vehicle, e.g.,
under the hood. Combined use is possible for all modules
of the two hardware series. All measurement modules
are integrated with INCA. In parallel with measurement
modules, ETAS ECU and bus interfaces can be connected
to the compact ES600 or ES51x network modules. As an
alternative to INCA, an ES715 Drive Recorder can be used
to log measurement data.
ETAS measurement modules supply the user with
accurate measure values. Thanks to extremely low
temperature coefficients and the electrical isolation of
individual measurement channels, measurement readings are largely independent of ambient temperature
and ground loops.
Network Modules provide for combining measuring
devices to form a cluster and synchronizing them featuring microsecond accuracy. Measurement channels behave
exactly the same, regardless whether they belong to one
module or as part of a device cluster. Based on Ethernet,
measurement clusters are capable to transfer high data
volumes to the host application. To optimize each measurements time resolution and data rate, each channel
features an individually adjustable data acquisition rate.

ES600 Measurement Modules

The metallic housings of the ES600 module family are
rugged, compact and easily handled. In standalone
operation, a measurement module is connected directly
to the PC and to the power supply with the use of a Y
splitter cable. Using a built-in power saving feature, the
modules of the ES600 family automatically switch to
standby mode if no PC is connected.
ES600 devices quickly interconnect, simplifying the
assembly of a module stack with up to six measurement
modules. The measuring channels in one stack are
connected and time synchronized by a network module.
In addition, the ES600 Network Module supplies power
to each of the connected measuring devices, with the
modules being powered up sequentially to prevent load
surges. The network module continuously displays the
activities on the connecting line to the connected devices
via LEDs, making it possible to monitor the operation of
both the module and the connection itself.
In equal measure, ES600 Network Modules provide for
combining and synchronizing of up to six device clusters.
One single cable carrying power and Ethernet signals
connects the PC to the governing network module.
Separate clusters can be placed at separate locations,
e.g., in the trunk of a vehicle or in the cabin floor area.
The star topology tolerates the failure of an ES600
module or cluster and offers easy maintenance of the
measuring setup. In a complex setup, the user can cause
an identification LED to illuminate in order to spot a
specific module.

37

ES400 Micro Measurement Modules

Sensor signals usually require long cable runs to connect
with measurement modules. In the vehicle, this means
routing heavy cable harnesses through the bulkhead
into the vehicles interior. This wiring technique not only
calls for extensive modifications of the vehicle body the
substantial installation and setup efforts also represent a
significant cost factor.
With the measurement modules of the ES400 product
family, ETAS provides a solution that overcomes the need
for destroying the vehicle body to run sensor cables. The
ES400 modules are designed for installation in the immediate proximity of sensors or signals being measured.
ES400 module housings are water and dustproof as
per IP67 and impervious to acceleration and impact,
such as from flying rocks. All connectors are water and
dustproof. The modules feature a working temperature
range of between 40 F and 248 F (40 C and +120 C).
The modules very small form factor facilitates installation even in otherwise unsuitable voids and corners of
the vehicles engine compartment, body, or chassis. This
minimizes sensor cable lengths which reduces signal distortion and eliminates long sensor cable harnesses. Only
a single data acquisition cable has to enter the vehicles
interior through a keyhole.

38

Established practice with modular test bench concepts is

to mount the test candidates on pallet systems, and to
set up the required connections with the test bench using
predefined interfaces. To save valuable test bench time,
test objects engines, for example are equipped with the
necessary sensors and measuring modules prior to their
installation at the test bench. The arrangement of modules
in close proximity to the sensors and the fact that the data
cable represents the only interface to the test bench host
computer allows for an easy check of the measurement
setup on the pallet offline. The modules of the ES400 family are ideally suited to test bench deployment thanks to
efficient test preparation plus their immunity to ambient
conditions in terms of vibrations, oil vapor, exhaust gas,
and water, which are often present at test benches.
ES400 measurement signals can be accessed by ES715
drive recorders. In addition, ES400 modules are fully
integrated with the ES910 Rapid Prototyping Module
and provide signals to function prototypes in real time.
By use of the standardized XCP-on-Ethernet protocol
and a standalone configuration tool provided by ETAS,
ES400 modules can be easily integrated with any thirdparty applications. A C-based library is available for
integration into software applications that dont provide
XCP-on-Ethernet drivers. Currently, ES400 modules are
supported by the applications MM6 from Robert Bosch
Chassis Systems Control, DEWESoft from DEWETRON,
PROVEtech: VA from MBtech Group, and CANape from
Vector. Drivers for LabVIEW are also available.

ES410

ES411

ES420

Hardware Component

Measurement Channels

ES410 A/D Module

8 x Differential voltage

ES411 A/D Module with Sensor Supply

4 x Differential voltage, including sensor supply

ES420 Thermo Module

8 x Universal thermocouple inputs

ES430/ES432 Lambda Module

1 x Oxygen sensor input

ES441 Counter and Frequency Module with

SensorSupply

4 x Counter, timer, or f requency inputs

Table 4:
ES400 Micro Measurement Modules measurement channels.

ES430

ES432

ES441

39

ES715

4.4 Unattended Logging of

INCA Data
Alternative to an INCA-PC, the ES715 Drive Recorder
provides for the logging of data from ETAS ECU and bus
interfaces and measurement modules. For standalone
operation, the ES715 module contains two onboard CAN
channels. Configuration and retrieval of measurement
data is done via an easy to use web interface. The ES715
Drive Recorder runs INCA experiments, but can also be
operated if the user is not familiar with INCA. LEDs on
the front panel of the device display the measurement
status.
The setup of the desired measurement parameters is
achieved by the creation of an XML file via an INCA
experiment environment. ES715 mass storage can be
extended by USB memory devices.

ES600

ES592

ES650

ES432

40

Figure 15:
The ES715 Drive Recorder can be connected via an ES592/ES595 Interface Module to multiple
ETAS measurement and calibration modules.

41

42

5. Application Engineering Services

ETAS premium engineering services are based on many

years of experience in automotive electronics development. Our globally networked experts provide a broad
range of skills. To support our customers in optimizing
processes, methods and tool environments, ETAS Application Engineering Services offer training and consulting as
well as development, setup, maintenance, and operation
of solutions.
Training
ETAS conducts training at its local training centers or at
the customer site. Courses offered range from standardized product training to customized arrangements and
coaching to integration support of new process solutions.

Examples for MCD engineering solutions are:

Integration of existing assets such as drive recorders or
measurement hardware
Setup of cold start measuring systems
Construction of ECU signal stimulators
Connection to data backbones
Support of specific serial protocols such as GMLAN,
TP2.0
Creation of data converters for proprietary formats
Customization of data visualization and analysis
Tools for specific purposes such as programming and
validation of diagnostic sequences
Implementation of customer-specific flash programming

Consulting

Operations

Our consultants provide our customers with professional

advice concerning the efficient use, setup, and migration
of tools.

Following installation at the customer site, ETAS application engineers are available to provide expert advice to
customer projects, e.g., during tool migration.

Customer specific solutions

High-value customer solutions complete the ETAS

portfolio of premium measurement, ECU calibration,
and diagnostics products. All ETAS engineers are globally
networked, service oriented, and focused on our local
customers.

ETAS customizes software and hardware products and

integrates them into the customer tool environment.
Our engineers can develop complete solutions including
products from third parties. Upon request, ETAS can also
install solutions on site. Maintenance services ensure the
availability of custom solutions and include adaptations to
additional requirements.

43

Contact addresses
ETAS GmbH
Borsigstrae 14
70469 Stuttgart, Germany
Phone +49 711 89661-0
Fax
+49 711 89661-106
sales.de@etas.com
ETAS S.A.S.
1, place des Etats-Unis
SILIC 307
94588 Rungis Cedex, France
Phone +33 1 567000-50
Fax
+33 1 567000-51
sales.fr@etas.com
ETAS Ltd.
Unit 2A
Meteor Business Park
Meteor Centre
Mansfield Road
Derby DE21 4SU
United Kingdom
Phone +44 1332 253770
Fax
+44 1332 253779
sales.uk@etas.com
ETAS Inc.
3021 Miller Road
Ann Arbor, MI 48103, USA
Phone +1 888 ETAS INC
Fax
+1 734 997-9449
sales.us@etas.com

ETAS K.K.
Queens Tower C-17F
2-3-5, Minatomirai
Nishi-ku
Yokohama 220-6217, Japan
Phone +81 45 222-0900
Fax
+81 45 222-0956
sales.jp@etas.com

Vetronix Corp.
2030 Alameda Padre Serra
Santa Barbara, CA 93103
USA
Phone +1 805 966-2000
Fax +1 805 965-3497
sales.us@etas.com

ETAS Korea Co., Ltd.

4F, 705 Bldg. 70-5
Yangjae-dong, Seocho-gu
Seoul 137-889, Korea
Phone +82 2 5747-016
Fax
+82 2 5747-120
sales.kr@etas.com
ETAS (Shanghai) Co., Ltd.
24F, Bank of China Tower
200 Yincheng Road Central
Shanghai 200120, P.R. China
Phone +86 21 5037 2220
Fax +86 21 5037 2221
sales.cn@etas.com
ETAS Automotive India Pvt. Ltd.
No. 690, Gold Hill Square, 12F
Hosur Road, Bommanahalli
Bangalore 560 068, India
Phone +91 80 4191 2588
Fax
+91 80 4191 2586
sales.in@etas.com

www.etas.com

ETAS/COM_Sar/03.2010