Robert BOSCH GmbH, Automotive Electronics
Design Requirements
for Automotive Reliability
Valentin von Tils
Director Platform Development ASICs
Automotive Electronics
1
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such as copying and passing on to third parties.
ESSDERC 2006,
Montreux, Switzerland
September 22, 2006
Design Requirements for Automotive Reliability
Automotive Electronics in German Newspapers (2003)
Automotive Electronics
2
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal
such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Outline
Î
Journey from Yesterdays Vision to Today‘s World
Î
Requirements for Future Systems
Î
Expected Market Trends
Î
Reliability Trends
Î
Impact on Power Semiconductors
Î
Summary
Automotive Electronics
3
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal
such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
1960: Vision
source: R. Bosch GmbH, Dr. Callsen, „The Importance of Semiconductors for the
Electrical Vehicle Equipment“. FISITA congress, 1960.
“The development of semiconductors is just at the
beginning…
Using semiconductors, ideas like
electronic gasoline injection as well as
control systems that allow steering, accelerating
and braking through a small control stick, or
steering systems that guide the car automatically
on the road, or radar units that show obstacles
even in dense fog, as well as some others, can
become reality…
Electronics is starting to change and to improve the
electric vehicle system and is thus adding
increased safety to the car.”
Automotive Electronics
4
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Automotive Electronic Yesterday ...
Automotive Electronics
5
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Semiconductor History 20th Century
90‘s
80‘s
70‘s
60‘s
50‘s
Germanium
Diode
Development
&
Start of Mass
Production
Silicon Diode
Mass Production
IC
Mass Production
MOS-IC
Development
MOS-IC
Mass Production
Opening of Micro
Electronics
Technical Center
Pressure Sensors
Mikro Mechanical
6“-Wafer Fab
Opening
IC
Development
50 years of
Automotive Experience
Automotive Electronics
6
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Milestones of automotive technology
Low-voltage magneto ignition for vehicles
High-voltage magneto ignition with spark plugs
Diesel injection pump
Acquisition of Ideal-Werke, today's Blaupunkt GmbH
Gasoline injection pump for cars
1897
1902
1927
1933
1951
1967
1976
1978
Electronic gasoline injection (Jetronic)
Lambda sensor for three-way catalytic
converter
Antilock braking system
(ABS)
Automotive Electronics
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Milestones of automotive technology
Combined digital control of gasoline injection and ignition (Motronic)
• Electronic diesel injection (EDC)
• Traction control system (TCS)
Controller Area Network (CAN)
• Electronic stability program (ESP)
• Vehicle navigation system with voice guidance
1979
1986
1991
1995
1997
2001
2002
2003
Common-rail high-pressure injection system for diesel engines
Electrohydraulic brake
Electronic battery
management (EBM)
Third generation common-rail
technology, with piezo in-line
injectors
Automotive Electronics
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Traction Control System
Airbag electronics,
safety belts,
over-roll Bar
Cruise Control
Navigation
ParkPilot
ca. 30 electric/electronic systems,
50-100 micro processors,
>100 sensors
within modern mid-size cars
Electronic
power steering
Chassis Control
Anti-lock Braking System
Engine
Management
Interior Sensing
Emission control
Electronic Stability Program
Automotive Electronics
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Traffic Density vs. Car Safety
% Change (1970 = 100%)
300%
Traffic Density
Total Accidents
250%
Injured
Killed
200%
150%
100%
SeatBelts
50%
ABS
Airbag
SideAirbag
ESP
0%
1970
1975
1980
1985
1990
1995
2000
2005
Sources: “Statistisches Bundesamt“ and Bosch
Automotive Electronics
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Reduction of Pollution (caused by cars)
State-of-the-art
2004
100
%
0,27
EU1
88/436/
EEC 0,196
0,14
50
0
100
50
0
100
50
0
Particles
5,8
ECE R
15/04
HC + NOX
81%
EU2
0,10
EU3
1990
EU4
0,05
0,025
90%
1,36
0,97
0,90
95%
0,56
21,2
ECE R
15/04
CO
91%
97%
2,72
1995
1,0
98%
0,64
2000
0,30
0,50
2005
all numbers = limit values in g/km
Automotive Electronics
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Reduction of Fuel Consumption
11,0
35%
Fuel consumption [l/100km]
10,5
10,0
9,5
9,0
8,5
8,0
7,5
7,0
Catalyser
6,5
Common
Rail
BDE
Diesel DI
E-Gas
6,0
12
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such as copying and passing on to third parties.
2002
2000
1998
1996
1994
1992
1990
1988
1986
1984
1982
1980
1978
Automotive Electronics
1/3-Mix
NEFZ
Source: VDA
Design Requirements for Automotive Reliability
„Intelligent Vehicle“
A
Sy irba
ste g
m
Human
Machine
Interface
"Intelligent
Sensors"
Kinetics
iron
Env t
men
l
na
r
e
int ata
d
e
ak
Br tem
s
Sy
ring
Stee m
e
Syst
Vehicle
Functions
Coordination
Monitoring
Pos
ition
Fusion,
Consolidation
Te
ma leInf tic
o.
Engine
Tran
miss sion
.
m
er m
Th ste
Sy
E
Sy lectr
ste .
m
Automotive Electronics
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such as copying and passing on to third parties.
"Intelligent
Actuators"
Design Requirements for Automotive Reliability
Outline
Î
Journey from Yesterdays Vision to Today’s World
Î
Requirements for Future Systems
Î
Expected Market Trends
Î
Reliability Trends
Î
Impact on Power Semiconductor
Î
Summary
Automotive Electronics
14
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
The Future of Automotive Electronics
“The number of ECUs in the car will decrease ?“
Î Answers of the car manufacturers: The number of ECUs will decrease
does not mean: The functionality given by electronics will decrease!
Means:
Î Number of ECUs may decrease in order to
z Manage the complex electronic system
z Reduce the number of failure sources
z Make the system more reliable
z Limit the cost
Automotive Electronics
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Automotive Electronics Roadmap
Digital Systems, Integration, Networking
Networking of ECUs
Components
with Electronic
1980
SystemIntegration
1990
Networking of Cars and
Environment
2000
2010
Safety, Environment, Fun & Comfort
Automotive Electronics
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AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal
such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Networking with Environment
Broadcast (terrestr.)
Satellite Broadcast
Cell Phone
GSM/
UTMS
Module
Services
platform
Car
Radio
Module
Bluetooth
W-LAN
In-car or
small distance
Automotive Electronics
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
The next big step: „The sensitive vehicle“
„ Combination of
intelligent surround
sensors with active
and passive
safety systems
„ Contribution to reduce
fatalities by 50%
(EU e-safety goal)
Automotive Electronics
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Integrated Vision System: Applications
NightVision
Lane Detection
Object Detection
Road Sign Recognition
Automotive Electronics
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Challenges for Automotive Electronics
Î
Convergence of Systems
- new functions often require networking of different systems
- systems accessible from outside (wireless)
- need to integrate subsystems of different suppliers
Î
How to keep vehicles – despite their increasing electronics content –
affordable for the consumer ?
Î
How to assure extended lifetime reliability and availability of the
vehicles despite the underlying very complex electronic systems ?
Automotive Electronics
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AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal
such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Requirements on Automotive Semiconductors
Parameter
Consumer
Industrial
Automotive
temperature
0°C Æ 40°C
-10°C Æ 70°C
-40°C Æ 85/155°C
operation time
1-3 years
5-10 years
up to 15 years
humidity
low
environment
0% up to 100%
tolerated field
failure rates
< 10%
<< 1%
target: zero failure
documentation none
conditional
true
supply
up to 5 years
up to 30 years
none
Automotive Electronics
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AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal
such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Increasing Temperature Requirements
Drivers:
ƒ rising temperatures
Ambient Temperature
C°
under the hood
Automotive
150
ƒ rising power dissipation
of microcontrollers
125°C
ƒ rising control units‘ loads
ƒ higher component
50
integration into smaller
packages
Consumer
1992
1996
2000
2004
2008
2012
ƒ more applications in
difficult locations
Automotive Electronics
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Temperature requirements
for automotive semiconductors
Silicon inside
of the actuators
Silicon separate
of the actuators
Tj < 175°C
Tj < 210°C
3000
operating life time (h)
Silicon adjacent
to the actuators
2500
2000
1500
1000
500
0
130
Tj < 150°C
1995
170
190
temperature (°C)
2005
Automotive Electronics
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150
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such as copying and passing on to third parties.
2010
210
Design Requirements for Automotive Reliability
Environmental Temperature °C
Operating Conditions for Automotive Control Units
ABS/ESP
TC
application
160
EPS
140
120
PECU
100
EM
80
EM
60
40
PCB
PCB
on
Metal
Potential
µ Hybrid
20
0
20
40
60
80
Peak Acceleration g(Sinus)
EM = Engine Management, TC = Transmission Control,
EPS = Electrical Power Steering, PECU = Pump Electronic Control Unit
Automotive Electronics
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AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal
such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Intelligent Actuator: Control Unit for
Electrical Power Steering (EPS)
Features:
Compact design
Î using automotive specific
LTCC and DBC technologies
Î temperatures up to 125°C
Î current up to 100 A
Î mounting direct at the steering gear
Î acceleration (shock) up to 40 g
Î
Automotive Electronics
25
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal
such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Outline
Î
Journey from Yesterdays Vision to Today’s World
Î
Requirements for Future Systems
Î
Expected Market Trends
Î
Reliability Trends
Î
Impact on Power Semiconductor
Î
Summary
Automotive Electronics
26
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal
such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Automotive Electronics: Installation Rates (WEU)
%
Lambda Sens.
ABS
Airbag
Navigation
E-GAS
Diesel DI
Xenon
ESP
BDE
Climate Control
1976 1978 1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002
Automotive Electronics
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Automotive Electronic Sales by Region
70
59.6
60
55.6
50
Billions of Dollars
Part of Total CAGR
2003 2012 ‘03/’12
64.0
43.2
37.0
40
45.9
48.8
Asia/Pac 12% 21% 12.3%
51.9
39.6
30.1
Europe
36% 39%
7.8%
Japan
25% 21%
4.1%
Americas 27% 19%
4.9%
World total
7.1%
30
20
10
'03
'04
'05
'06
'07
'08
'09
'10
'11
'12
Source: Bosch
Automotive Electronics
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Automotive Semiconductor Sales by Region
40
Part of Total CAGR
2003 2012 ‘03/’12
34,2
35
31,3
28,6
Billions of Dollars
30
Asia/Pac 8%
22% 14.9%
26,2
24,1
25
20,4
20
15
17,0
22,1
18,4
Europe
39% 41%
9.8%
Japan
19% 18%
5.8%
Americas 34% 19%
6.5%
World total
9.6%
13,7
10
5
'03
'04
'05
'06
'07
'08
'09
'10
'11
'12
Source: Bosch
Automotive Electronics
29
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal
such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Outline
Î
Journey from Yesterdays Vision to Today‘s World
Î
Requirements for Future Systems
Î
Expected Market Trends
Î
Reliability Trends
Î
Impact on Power Semiconductor
Î
Summary
Automotive Electronics
30
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal
such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Reliability Requirements
Î
Reliability = (1 - probability of a failure) per electronic device
- at 0 km
- in the field over a given period of time
Î
Increasing realibility demands due to higher usage of electronic
devices in vehicles
Î
Car industry requirement:
For each ECU:
Î
0-km and field failure rates < 10 ppm/year
Derived requirement:
for each component: 0-km and field failure rates < 1 ppm/year
Automotive Electronics
31
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal
such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
How to reach reliability against early failures
Assignment and control of ppm limits for each step of the value
creation chain:
Î
Assignment and control of ppm limits for each electronic component
depending on its complexity
Î
Agreement with all suppliers about ppm limits
Î
Application of systematic in-process quality assurance measures
throughout the value creation chain
Î
Intensive “quality mindset” training of all employees
Î
Tight control of failure rate development - regularly followed with high
management attention
Automotive Electronics
32
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Breakdown of ECU ppm reliability requirements
(simplified, example values)
ECU -failure
0
faulty design/SW
10
„Mass production
failure“
/ bad material
the future.
7
0-Defect will be the
game
of
Electronic
3
And this will
be judged
by the
components
(EC)
ECU plant
customer
only.
0
7
EC mech..+
EC-Logistics
0,2
ASIC
0,5
µC
0,2
ASIC
0,1
Flash
...
0,02
Inductors
Automotive Electronics
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such as copying and passing on to third parties.
0
Logistics
0
R
0
MLCC
Design Requirements for Automotive Reliability
Reliability against Aging Failures:
Operating Conditions of Automotive Electronics
Î
Î
Thermal:
z
operating temperature range
z
number and stroke of temperature cycles over lifetime
Mechanical:
z
Î
vibration load – peak mechanical accelerations
Climate/Environment:
z
humidity and corrosive substances (salt, fluids, vapors…)
Σ vehicle application dependent
Automotive Electronics
34
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Systematic Design for Reliability
Definition of technology, design
and components for the application
(1) Describe known failure mechanisms by
mathematical models using parameters
from prior end-of-life testing
(2) Determine the real-life, application
specific “load profiles” from vehicle
testing
(3) Simulate the field reliability
using the failure models (1) and
the real-life load profiles (2)
Verification of technology, design
and components for the application
(6) Do additional end-of-life testing
for further design confirmation
and verification / improvement
of failure models.
(5) Perform release testing for
confirmation of the life-time
reliability of the design
(4) Define (shortened) release test profiles
using physical failure models (1) and
application load profiles (2)
Automotive Electronics
35
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal
such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Outline
Î
Journey from Yesterdays Vision to Today’s World
Î
Requirements for Future Systems
Î
Expected Market Trends
Î
Reliability Trends
Î
Impact on Power Semiconductor
Î
Summary
Automotive Electronics
36
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal
such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Die Kraft der Luft
Sunroof
Air Condition
Wiper
Rear Window
Defroster
Convertible
Roof
Injectors
Active Valve
Adjustment
Active
Suspension
Fan
Control
Window Lifter
Mirrow
Adjustment
Adaptive
Seat Position
Active
Steering
Front
Control
Throttle
regulation
Light
Automotive Electronics
37
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Impact on Power Semiconductors
Î
Power Semiconductors are used in safety critical applications
(i. e.: x-by-wire)
Required
Î
Continuous control of parameters, that show critical operation conditions:
voltage, current, temperature
Î
On site / attached control logic to ensure safe operation
Automotive Electronics
38
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Domain based systems architecture
Central
Domain ECU
Intelligent
Satellite
Sensors
Intelligent
Satellite
Actuators
Peripherie
Peripherie
Bus
standard
components
automotive specific semiconductor solutions
(ASSP, SoC, ASIC, MEMS)
Automotive Electronics
39
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such as copying and passing on to third parties.
Power
Control
µCµC
++
µC
+
Memory
Speicher
Speicher
Peripherals
Bus
Peripherie
Peripherie
Peripherals
Sensor
Sensoren
Sensoren
SignalSignalConditioning
SignalAufbereitung
Aufbereitung
Inter Domain Bus
Actuator
Steller
Steller
Design Requirements for Automotive Reliability
Control Circuitry in High End Ignitor (SoC)
Vfl
Over voltage
Flag
B
C
Overheat
Limiter
Voltage
clamping
Driver-Stage
Overheat
Protection
Current
Flag
Current
Control
Ifl
Automotive Electronics
40
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such as copying and passing on to third parties.
E
Design Requirements for Automotive Reliability
Current Regulator and Tolerances
Standard Solution Current Regulator:
3. A/D Converter
2. Signal Processing
U+
• Quantization Error/ Noise
• Offset
• Gain Error due to Reference • CMRR (Common Mode Rejection Ratio)
• Gain
• Anti Aliasing Filter (Nyquist –Criteria)
Reference
A/D
Converter
Signal
processing
actual Value
Ucm
Driver
Unit
Set Value
4. Controller
• Quantization Error
Automotive Electronics
41
RShunt
1. Shunt
Udiff + CMMR * Ucm
µc
Udiff
Load
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such as copying and passing on to third parties.
• Tolerance %
• Tolerance Tk
T1
Design Requirements for Automotive Reliability
CG208: Fully integrated Low Side Current Regulator
Application:
High precision low cost current regulator
for e.g. transmission control valves
Features:
ASIC Name:
SOP:
Package:
Process:
• Dual channel current regulator
• Temperature monitor
• Fully integrated current controllers
• Low Side power switches
• Integrated shunts and
• Free wheeling diodes
• Current range up to 1,2A
• High accuracy (∆I < 1%)
• SPI controlled load current
• SPI controlled dither ampl. and freq.
• SPI controlled loop characteristics
• Fault detection and protection
(additional load and µc clock monitor)
CG208
Jan. 2007
Bare die, TQFP_ePad44
BCD4S
Automotive Electronics
42
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal
such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Outline
Î
Journey from Yesterdays Vision to Today‘s World
Î
Requirements for Future Systems
Î
Expected Market Trends
Î
Reliability Trends
Î
Impact on Power Semiconductor
Î
Summary
Automotive Electronics
43
AE/EIP | 7/8/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal
such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Summary
Î
The trend towards more comfort and more safety will continue.
Î
Customer expectations and legal requirements will require
“fault tolerant” systems.
Î
Diagnostic capability will be mandatory for future electronic
systems.
Î
Intelligent, redundant systems have to be developed.
Automotive Electronics
44
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such as copying and passing on to third parties.
Design Requirements for Automotive Reliability
Thank you!
Automotive Electronics
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