With the continued spread of Coronavirus (COVID-19), Dana is committed to ensuring that our products and services to our global customer base continue with the minimum possible interruption. In support of this effort, we have implemented the following precautionary measures:
- Communication with our customers and business partners is ongoing via our electronic and digital channels.
- As of this week, the majority of our employees are working from home. They continue to be accessible via email and phone during normal business hours.
- Digital platforms are being used for all meetings.
- Guidelines on conduct and precautionary measures are being communicated to employees on an ongoing basis.
- The staff critical to the supply of Dana products is continuing to work to ensure supply for our customers.
- Dana’s contract manufacturing partners continue to operate and plan to continue to support your production needs.We are confident the measures we are taking will allow us to continue to deliver our products and services to customers in a safe and efficient manner. We remain open for business, committed to be responsive and maintain our passion to serve our customers.
Sincerely,
Walter Lucking
CEO, Dana
The M560/M580 has been certified by TÜV SÜD against ISO 26262-2018 as a safety element out of context up to ASIL D. The Electronic Control Units (ECU) are industry proven with features tailored for integrated Vehicle Control Unit (VCU) and Vehicle Charge Control Unit (VCCU) 12-volt and 24-volt applications, along with Dana’s OpenECU-FS platform software.
The certification process verified achievement of functional safety to ISO 26262 across all aspects of the development lifecycle including:
![ISO 26262 development lifecycle](https://openecu.com/wp-content/uploads/2020/03/Microprocessor.png)
Overview of the ISO 26262 series of standards
Functional safety management, safety lifecycle, and supporting processes (ISO 26262 parts 2, 8)
- Safety culture
The certification included a review of the Dana culture, including staff qualifications and training records to verify our focus on functional safety and quality. - Quality management system
The certification reviewed and verified the Dana commitment to maintain a world-class quality management system through its ISO 9001:2015 Business Management System. This includes documented and audited processes for project management, change management, documentation management, configuration management, and more. - Safety management
The certification reviewed the safety plan for the M560/M580 ECU development. - Tool Qualification
The certification covers the tool qualification of the tools used in the development of the M560/M580 and OpenECU-FS software as well as the guidance provided in the safety manual for application developers to stay within the qualification assumptions.
Product development at the system level (ISO 26262 parts 4, 10)
- Element Definition
Since the M560/M580 and OpenECU-FS software are safety elements out of context, the element definition including the assumed operating environment and the designated safety functions, including fault handling time intervals, were specified and approved. - Technical Safety Concept
The certification verified the technical safety concept, including the overall module architecture and safety mechanism definition. The safety mechanisms provided by the platform and those required to be implemented by application software are all defined in the M560/M580 functional safety manual. This also covers the element-level FMEA and FTA safety analyses. - Element Integration Verification
The certification reviewed the verification plan for the element against its defined safety functions and assumed the operating environment. This also covers the actual conducted DV/PV testing, as well as functional-safety, focused verification of the M560/M580 safety mechanisms with the hardware and OpenECU-FS platform software.
Hardware and software safety mechanisms (ISO 26262 parts 5, 8, 9)
- Hardware Design
The certification covers the hardware design, including both the 12-volt M560 and 24-volt M580 variants. - Safety Analyses (Hardware)
The certification covered the hardware component-level DFMEA, FMEDA, and dependent failure analyses. - Verification
The certification covers the DV and PV testing, evaluation of hardware components, functional testing, and fault insertion testing.
Product development at the Software Level (ISO 26262 parts 6, 8, 9)
- Software Design
The certification covers the design documentation for the OpenECU-FS platform software for both the primary and secondary microcontrollers, including traceability from software safety requirements to design and verification. - Safety Analyses (Software)
The certification covers the safety analysis of the software architecture per ISO 26262-6:2018 annex E; using techniques such as FMEA and HAZOP applied to software. - Verification
The certification covers the evaluation of all OpenECU-FS verification, including coverage metrics, unit testing, and on-target integration testing.
Quality assurance in production (parts 7)
- Certification includes an audit of our manufacturing partner and verification of processes for maintaining functional safety post-production.
![Dana Vehicle Control Unit VCU and VCCU: M560](https://openecu.com/wp-content/uploads/2019/01/m560.png)
Dana M560
To see how the M560/M580 and OpenECU-FS platform software can enable your production development for safety-related vehicle control, charging control, or other applications, contact Dana for the detailed safety manual and technical specification documentation.
In addition to the certification for the specific out-of-context safety functions, Dana has the complete design information and rationale for design decisions for the M560/M580. This information and understanding of the design of all the functions of the module can be used to help you use the module in your specific application, even beyond the explicit assumptions of use.
OpenECU® M560 & M580 EV Supervisory Controllers Now Available with CCS Software
![](https://openecu.com/wp-content/uploads/2019/12/Supervisory-Controllers.png)
With the OpenECU M560 or M580 Supervisory Controllers and CCS (Combined Charging System) control strategy software , customers get Vehicle Control Unit (VCU) and Charge Management Unit (CMU) functions integrated in one module i.e. two ECUs for the price of one. Dana’s CCS Control Strategies manage the charging session for AC charging and DC fast charging implementing Combined Charging System adhering to SAE J1772 and DIN 70121 standards.
OpenECU M670 with FPGA for Closed-Loop Control Using In-cylinder Pressure Measurement
The OpenECU M670 with FPGA provides the capability needed for advanced engine control applications, equiring complex cylinder pressure-based combustion calculations. It calculates burn rate and the efficiency of combustion within the time window of an engine cycle for the results to be used to adjust the injection and timing of the next cycle.
![](https://openecu.com/wp-content/uploads/2019/12/Pressure-Measurement.png)
Development of an ISO 26262 ASIL-D Custom ECU for Autonomous Vehicle
![](https://openecu.com/wp-content/uploads/2019/12/Autonomous.png)
A growing portion of Dana’s business is developing custom ECUs for our customers. A major automotive OEM with very compressed development timeframes chose Dana to develop a custom Electronic Control Unit (ECU) designed to meet ISO 26262 ASIL-D (Functional Safety), to be used for autonomous vehicle development fleet. Requirements included a 6-axis Inertial Measurement Unit with high precision, high stability and low
thermal drift, full dual redundant operation, and fail-operational robustness to single-point failure.
SMART, DDOT Become Proterra’s 100th Customer with Purchase of Proterra Battery-Electric Buses and Charging Systems
Dana congratulates Proterra on bringing electric vehicle technology to the Motor City when it recently announced the Suburban Mobility Authority for Regional Transportation (SMART) and Detroit Department of Transportation (DDOT) have agreed to purchase electric buses and chargers from Proterra, becoming the 100th customer for the company.
![](https://openecu.com/wp-content/uploads/2019/12/Proterra-Battery.png)
Dana congratulates Proterra on bringing electric vehicle technology to the Motor City when it announced in October 2019 that the Suburban Mobility Authority for Regional Transportation (SMART) and Detroit Department of Transportation (DDOT) have agreed to purchase electric buses and chargers from Proterra, becoming the 100th customer for the company. DTE Energy will work with DDOT, SMART and Proterra on the charging infrastructure. To date Proterra has sold more than 800 buses across 41 U.S. states and Canadian provinces and delivered more than 390 battery-electric buses. Proterra vehicles on the road have also achieved nearly ten million miles of service across North America.
DDOT will receive two 40-foot Proterra Catalyst® E2 Max buses, two Proterra® 125 kW plug-in chargers and one 500 kW overhead fast-charge system. SMART will receive four 40-foot Proterra Catalyst® E2 buses with DuoPower™ drivetrain technology, four Proterra® 125 kW plug-in chargers and one 500 kW overhead fast-charge system. DDOT and SMART provide high-quality, safe and cost-effective public transit to the southeast Michigan region. DDOT is the largest public transit agency in Michigan providing service to the city of Detroit and neighboring cities and SMART operates primarily in suburban areas. SMART and DDOT were awarded $2.6 million through the Low- or No-Emission Vehicle (Low-No) Program from the U.S. Department of Transportation Federal Transit Administration for the electric buses and charging systems. The Proterra electric buses are the first electric buses for both organizations and the Proterra vehicles will replace aging diesel buses.
“SMART has long been interested in adding alternative fuel buses to our fleet, and the all-electric bus project is a big step into the future for transit in southeast Michigan.” said John C. Hertel, General Manager, SMART. “Battery-electric buses not only help us meet our sustainability goals, but provide a better rider experience while delivering cost savings.”
“Electric buses are a great addition to our fleet and sustainability initiatives that will continue to improve the transit experience for our communities,” said Angelica Jones, Interim Director of DDOT. “It is a great example between the public, private sector and DTE to bring clean and efficient transportation to metro Detroit.”
DTE Energy will work with SMART, DDOT and Proterra to provide the utility infrastructure necessary for charging the buses while on-route and at the respective terminals. Proterra and DTE Energy also recently announced a project to provide battery-electric school buses to Michigan schools for pupil transportation and to conduct a vehicle-to-grid pilot program.
“We’re excited to once again be working with Proterra to deliver the benefits of electric vehicle technology to Michigan,” said Sean Gouda, manager of DTE’s Electrification Business Development. “DTE Energy is a leader in clean energy initiatives, and we see transportation as a great opportunity to grow our sustainability efforts throughout the state. We commend DDOT and SMART for expanding clean transportation options in our region.”
Proterra has consistently advanced electric vehicle technology to tackle the needs of transit agencies across North America. One of the most impressive features of a Proterra battery-electric bus is the drivetrain and propulsion system that enable fuel economies of up to 25 MPGe, compared to conventional combustion engines that typically only get about 3.6 MPG. In addition to excellent fuel economy, Proterra battery-electric buses have eliminated range anxiety by engineering a bus that can hold up to 660 kWh of battery capacity and reach up to 328 miles of operating range.
In addition to battery-electric buses, Proterra provides purpose-built high-power charging systems for heavy duty EV fleets. All charging systems utilize standardized technology so customers could charge a range of electric vehicles on the same Proterra charger. In addition to the charging hardware, Proterra offers a full suite of options to enable turn-key delivery of a complete energy ecosystem for heavy-duty electric fleets including design, build, financing, operations, maintenance and energy optimization with Proterra Energy™ fleet solutions.
“Proterra has reached an incredible milestone of bringing clean, quiet transportation to 100 customers across North America,” said Proterra CEO Ryan Popple. “From the vehicle design and battery technology to heavy-duty charging systems and energy solutions, Proterra has been a pioneer in electrifying the transit industry. More than any other form of transportation, battery-electric buses are the cornerstone in addressing the future of mobility and sustainability for cities, and we believe the most exciting EV developments are happening in the North American electric bus industry.”
About Proterra:
Proterra is a leader in the design and manufacture of zero-emission, heavy-duty electric vehicles, enabling bus fleet operators to significantly reduce operating costs while delivering clean, quiet transportation to local communities across North America. The company’s configurable Catalyst platform is designed to serve the daily mileage needs of a wide range of transit routes on a single charge. With industry-leading durability and energy efficiency based on rigorous U.S. independent testing, Proterra products are proudly designed, engineered and manufactured in America, with offices in Silicon Valley, South Carolina, and Los Angeles. For more information, visit: http://www.proterra.com and follow us on Twitter @Proterra_Inc.
Click here for Proterra Press Release
The session presents Dana’s experience of developing an Autonomous Vehicle Custom ECU with modern application software testing using VectorCAST. Dana developed a custom embedded controller for autonomous vehicle application.
The embedded controller developed was based on the following high-level requirements:
- Functional safety (ISO 26262)
- Full redundant ASIL-D
- Fail-operational robustness to single-point failures (internal redundancy)
- Data transmission using 100BASE-T1 automotive ethernet (2-wire)
- Data time stamping asynchronous sensor readings, based on vehicle’s master clock module
- Measurement and processing of high-resolution wheel position encoders
- 6-axis Intertial Measurement Unit (IMU) for vehicle altitude control
- High precision
- High stability
- Low thermal drift
The presentation focuses on integration of VectorCAST and Simulink in software testing to achieve high-integrity software for autonomous applications.
Jeff Lovell, Systems Engineer at Dana presented the session on June 12, 2019, at the second Software Testing Symposium in San Jose, California hosted by Vector.
Plymouth, MI- June 17, 2019 – Dana congratulates Roush Clean Technology for its deployment of the 20,000th propane autogas vehicle and having crossed the one billion miles milestone driven across the U.S. and Canada.
Roush Cleantech’s propane autogas fuel system is engineered to California Air Resources Board’s lowest ultra-low NOx standard of 0.02g, making it 90 percent cleaner than the strictest EPA standard. Vehicles with this engine are 99 percent cleaner than diesel vehicles built before 2007.
Dana applauds vision-friendly organizations that foster and create greener technologies.
For more information, please visit: https://www.roushcleantech.com/1-billion-miles-and-rolling/
Download PDF version here.
ABOUT Dana
Dana LLC has been in the United States since 1990. The OpenECU product family (Model-Based development Software Platform) is Dana’s signature product family and by 2019 there were more than 40,000 OpenECU based ECUs on the road in production vehicle applications.
Information about Dana and its products in the USA is available to journalists online at https://openecu.com.
The difficulty with diagnostics is in the definition.
- Do the diagnostics report simple wire harness shorts and opens checks?
- Do the diagnostics report ECU pin function checks and possible intermediate stuck at voltage checks?
- Do the diagnostics perform initial checks at power-on, or real-time and run-time checks of the internal ECU health and function?
- Are the diagnostics the complex rationality and long-term diagnostics of system (not just ECU) function related to regulatory compliance?
- Finally, are any of the diagnostics of functions associated with safety?
The answer is usually “yes to all the above”.
Basic Pin Diagnostics:
For most embedded control systems, the minimum price for entry is basic short circuit and open circuit diagnostics for all outputs. Inputs are more nuanced as the valid states for a typical switch input are “open circuit” and “short to battery” or “short to ground”. Fully diagnosable switch input circuits require switches which transition not between open and closed, but rather between two distinct closed states (distinct resistances to battery or ground) and are diagnosed with an analog voltage measurement. Measuring the analog voltage at the pin and comparing that to the expected voltage given the currently assumed system state is typically at the core of basic robust pin diagnostics. For more constrained systems or lower diagnostic intensity a simple digital monitor can often provide enough information, and in instances where frequency-based signals are expected, the ability to measure in the time domain may prove useful. The entire OpenECU product line has at least the basic pin diagnostics as a starting point.
Output Driver Diagnostics:
Output drivers have an idle state and an actively driven state (or potentially two actively driven states for H-Bridge outputs). The basic pin diagnostics needs to be cognizant of the possible valid pin states and the current commanded state. Do the diagnostics require detection of faults regardless of the commanded state? Do the diagnostics require detection of intermediate faults (not a short to battery/ground but an over current condition which could be caused by a short internal to an inductive load)? These diagnostics start with the pin state monitor (typically analog voltage for low speed circuits and possibly a digital input into a timer channel for frequency or PWM signals) and then diagnostic application code needs to be written to make sense of the pin state data. This diagnostic application code is usually tightly coupled to the control application, as the interpretation of the pin state data is highly dependent upon the expected state, which for outputs is determined by the control application. The output driver diagnostics provided by the OpenECU product line combined with the basic pin diagnostics enable the higher-level diagnostics to be constructed in the application.
Rationality Diagnostics:
Rationality diagnostics are not faults that drive signals out of their expected ranges, but more typically a set of input values that together do not match with a rationally expected physical system, e.g. the air/fuel ratio sensor reads lean mixture even at full fuel pulse duration and partial throttle. These diagnostic applications typically require substantial knowledge of the physics of the system under control, and usually need a large engineering effort to calibrate the thresholds between normal operation and faulted state. Quite often these applications require that data be stored from repeated operating cycles of the system.
Functional Safety Associated Diagnostics:
Functional safety associated diagnostics are more a mindset than a separate category of diagnostic type, involving diagnostics of faults/failures that do not directly cause an issue with a required function (input or output), but rather with a safety measure. If your system has functional safety associated controls, then an analysis is required where the ECU design is reviewed in light of the system safety goals, and the diagnostics must be reviewed to confirm that any fault that could violate the safety goals can be detected.
It is important to understand that even full-featured ECUs like the OpenECU M560, which have extensive diagnostic capabilities, will likely require application development to implement higher-level system diagnostic functions. Development of these system-level diagnostic functions for ECUs requires knowledge of the measurements and modes available on the ECU, in addition to the behaviors and details of the system under control. Dana’s extensive OpenECU documentation provides the necessary detail for systems engineers to develop these diagnostics.
This 30-minute Webinar shares lessons learned during the development of several EV/HEV controllers including the M560 OpenECU – from prototyping through production – while satisfying ISO 26262 ASIL D safety goals. An overview of the development experience shows specific areas where satisfying ISO 26262 is not as technically difficult as it is culturally challenging. It also discusses the importance of balancing prototyping activities to support aggressive automotive project schedules with the diligence required for functional safety.
ABOUT Dana
Dana LLC has been in the United States since 1990. The OpenECU product family (Model-Based development Software Platform) is Dana’s signature product family and by 2019 there were more than 40,000 OpenECU based ECUs on the road in production vehicle applications.
Information about Dana and its products in the USA is available to journalists online at https://openecu.com.
When you see the name Dana, your first thought might be of the famous mathematical constant that begins with 3.14. If you read it too quickly, you might be reminded of Pinocchio, the delightful tale of a physically deformed puppet. But from now on, when you see Dana, here’s what you should think of: safe, simple and customizable Electronic Control Units (ECUs).
Dana began 27 years ago, evolving from a research project at Cambridge University to develop heavy-duty diesel engine control hardware and software. Today, the company produces custom embedded controllers for a variety of applications, including vehicle control units for EVs and hybrids. It has also developed electric parking brake controllers, Unmanned Aerial Vehicle (UAV) controllers for military applications, and a number of custom controllers for major OEMs.
ABOUT Dana
Dana LLC has been in the United States since 1990. The OpenECU product family (Model-Based development Software Platform) is Dana’s signature product family and by 2019 there were more than 40,000 OpenECU based ECUs on the road in production vehicle applications.
Information about Dana and its products in the USA is available to journalists online at https://openecu.com.