Universal ECU Adapter Module for Scalable Control Systems
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Solution Overview
Problem
The challenge lies in the obsolescence and high costs associated with manufacturing unique or derivative Engine Control Units (ECUs) due to their distinct form and fit requirements, leading to increased part numbers, higher piece part costs, and Non-Recurring Engineering (NRE) costs, as well as reduced product volumes and scalability across various applications.
Innovation Solution
The integration of adapter-connectors and adapter-modules with generic ECUs, which include pre-routed printed circuit boards (PCBs) and hermetic enclosures, allows for scalability by re-routing signals from a common PCB to application-specific connectors, enabling upgradability, replaceability, and backward compatibility while maintaining existing connector systems and module footprints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If unique or derivative ECUs are manufactured to accommodate various changing demands for ECU functionality, then ECU functionality is improved, but part number proliferation and manufacturing costs increase
Solution Approach 1:
The patent implements a universal ECU platform with standardized connectors and pin-outs that can serve multiple applications. By making the ECU design universal, the system can accommodate various changing demands for ECU functionality through software configuration and adapter modules rather than creating unique hardware designs for each application, thereby reducing part number proliferation while maintaining functional adaptability
Solution Approach 2:
The patent segments the ECU system into a universal base ECU unit and separate adapter modules. The base ECU contains common functionality, while specific application requirements are met through interchangeable adapter modules that connect to the standardized ECU interface. This segmentation allows functional versatility without requiring unique ECUs for each application
2Adaptability or versatility
If unique or derivative ECUs are manufactured with distinct form and fit requirements, then ECU functionality is improved, but piece part costs and NRE costs increase
Solution Approach 1:
The patent establishes a universal ECU platform with standardized connectors and pin-outs that can serve multiple applications. By making the ECU design universal, the system can accommodate various changing demands for ECU functionality through software configuration and adapter modules rather than creating unique hardware designs for each application, thereby reducing part number proliferation while maintaining functional adaptability
Solution Approach 2:
The patent uses a standardized ECU platform that can be copied and reused across multiple applications. Instead of designing unique ECUs for each application, the same base ECU design is replicated and adapted through software and adapters, significantly reducing Non-Recurring Engineering (NRE) costs and piece part costs associated with unique designs
3Adaptability or versatility
If adapter-connectors are integrated to the ECU, then scalability is improved, but device complexity is increased
Solution Approach 1:
The patent integrates adapter-connectors as nested components within the ECU structure. The adapter-connectors are incorporated into the ECU housing and connector assembly, allowing the ECU to be manufactured with built-in adaptability. This nesting approach enables scalability while managing complexity by consolidating the adapter functionality within the existing ECU form factor rather than adding separate external components
Data Source
AI summary
An engine control system includes an integrated engine control module assembly having an engine control module and an adapter module. The integrated engine control module assembly further includes a first connector, a second connector, and a hermetic enclosure. The first connector includes a connection circuit configured to connect the integrated engine control module assembly to engine hardware. The second connector is configured to connect the adapter module to engine hardware. The hermetic enclosure houses the engine control module and is configured to protect the engine control module from environmental conditions.