All modern commercial motor vehicles (CMVs) have an engine control module (ECM). The primary function of which is to control the engine’s performance, fuel efficiency, and emissions; to safeguard the engine from abuse; to troubleshoot mechanical problems; and to monitor the operation of the vehicle. An ECM is commonly referred to as an electronic control unit (ECU) for which an average modern CMV has 40 of and they control everything from gauge cluster dash control to air brake systems in the same manner as the ECM. Going back to the basics, all ECUs are essentially small-sized, dedicated computers. They have a microprocessor, built-in random access memory (RAM), signal-conditioning chips (for sensor inputs), output transistor/drivers (e.g., actuating ignition and fuel injectors) and a programmable read-only memory-type chip (PROM) for calibration purposes. Naturally, this short list does not describe the entire contents of the ECU but describe the essentials for updating purposes. Most engine power complaints and warning lights come from them and over time ECU updating is necessary for recalls, customer issue, and new software or firmware release.
It is well known in the industry that if the CMV has a check engine light on or is going into the shop for any reason, recalls/campaigns are checked prior to service. ECU updates and re-flashes are recognized in the industry for being most commonly performed due to OEM recommended efficiency changes. Even a brand new CMV out of the dealership at its premier level of service with minimal miles at its highest fruitful state of producing work can still have a recall for ECU update. Performing the software and/or firmware programming averagely takes between 30 minutes to an hour and is generally completed by a shop computer wired directly to the on-board diagnostics receptacle (e.g., J1979). Depending on the original equipment manufacturers (OEM) year, make, model, engine, chassis, transmission, etc. there could be multiple updates within a year to as many updates within a month throughout the year. There also could be several manual steps in completing a successful ECU update. Failing to follow any of the steps can result in ECU memory loss, damaging existing parameters, programming incorrectly, etc. resulting in extended downtime of the CMV.
Over-the-Air (OTA) programming is a solution to ECU updating by wirelessly communicating to the CMV embedded systems that require shop downtime. Just like an operating system upgrade to computer programs or a smartphone app alerting a new update is available and the decision to allow such action, the same opportunity can be possible for the future truck. With the mixing of ECUs and increased vehicle software complexity, over millions of lines of code, more than 50% of vehicle warranty costs are due to software glitches and electronic defects, causing OEMs to spend billions on warranty and recall costs. It also accounts for the unprecedented amount of fleet costs for vehicle downtime. OTA is a framework-based approach, built on a structured, extendable, internet compatible architecture to enable vehicle data management, as well as effective and efficient software and firmware updates to future CMVs.
In a connected vehicle setting that offer drivers the ability to stay connected with the world from the seat of their vehicle, it uses telematics and smartphone integration technologies for software Over-the-Air (SOTA), and firmware Over-the-Air (FOTA) updating. A typical update consist of creating the software/firmware update package, deploying it OTA, receiving it in the CMV device, and finally installing the software/firmware update package.
OTA update use cases:
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Embedded 3G/4G modem
OEM contracts with a mobile network operator to provide network services through its embedded modem in its vehicles.
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Embedded Wi-Fi
OEM adds Wi-Fi to access update via WLAN or mobile hotspot.
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Smartphone OTA using Bluetooth or wired tethering
OEM sends updates through OEM’s smartphone App. Customer tethers smartphone with radio/infotainment or telematics system either by wired USB connection or wireless Bluetooth connection to install update package.
Characteristics required with each use case:
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Security: Security is essential for ensuring a safe transaction of the data between the OEM server and the vehicle.
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Download speed: A high bandwidth network is preferred to ensure a fast and reliable download.
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User expense: Additional monthly payments can discourage customers from enrolling in an embedded vehicle data plan.
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Multiple devices: OTA updates have to be convenient and intuitive for the customer, if multiple devices and steps are required then the OTA use case is less attractive.
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Access of wireless reception: To ensure a reliable connection to the wireless network the customer must have reliable network reception.
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Infotainment/Radio or Telematics memory: For a reliable update, there should be sufficient memory to store the new package before installation. Without an increase of storage the new package will directly download into the flash and overwrite the old code, which can disable the system if connection is lost at any point during the download.
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Automatic “forced update” feasibility: Some customers might delay their updates several times until they find the convenient time to update. If an OEM has an urgent update that needs immediate implementation, a use case allowing the OEM to always have an access to the system will allow OEMs to better implement forced updates.
All three use cases “Embedded 3G/4G modem”, “Embedded Wi-Fi”, and “Smartphone OTA using Bluetooth or wired tethering” have their advantages and disadvantages. The best use case would be for the OEM and the customer to have a safe transaction of the update, at a very minimal labor and no added costs.
Best Use Case
When the OEM of an ECU system has developed an update that is OTA worthy, it sends the package to all fleets and owner operators telematics system personnel or company back office. After verification of the update and approval of supervising maintenance management, it is then wirelessly transferred OTA by best use case of the unit’s telematics network provider. At the beginning of a driver’s shift, possibly during pre-trip, at key-on-engine-off (KOEO) state the CMV telematics provider alerts the driver that an ECU or multiple ECUs have an update available. After the driver is done with their route or by following hours of service, he/she would be notified that their CMV is available for an OTA update (telemetrically). If and when all use cases are checked and update ready, the driver initiates the update by its preferred telematics provider before turning off the vehicle. Soon as the vehicle is turned off the package is delivered within a small amount of time (1 – 10 minutes). When the vehicle is ready to operate again and the ECU recognizes KOEO, the telematics system will alert the driver that the update package was delivered successfully. If the transfer is in any way corrupted by connection issues or any means the old ECU version is restored completely in its original state. Moreover, safety related ECU updates and recalls would be done at dealership or preferred maintenance facility to give more control over sensitive updates.
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