Project Background

A leading EPS controller manufacturer, in order to meet functional safety requirements, utilized ZC's functional safety library for the TC366 chip and the complex driver for the TLE35584. The solution implemented 55 features outlined in the TC366 safety manual, covering safety mechanisms relevant to the EPS controller, including LBIST detection, SRAM detection, Flash detection, MCU firmware detection, clock detection, register detection, DMA detection, STM detection, and more. Additionally, the project provided an End-to-End (E2E) protection protocol library, external watchdog driver interfaces, and SBC driver interfaces, ensuring the controller complies with ISO 26262 ASIL D standards. To support international expansion, the customer adopted an OEM-specified AUTOSAR protocol stack, for which ZC provided corresponding engineering services to ensure the stable operation of the AUTOSAR stack.

Technical Details

1. Core Focus of Software Development
   Based on the Infineon TC366 chip, ZC completed full-stack standardized configuration of AUTOSAR MCAL (including GPIO, CAN, interrupt controllers, etc.). In terms of safety mechanism integration, ZC leveraged the VECTOR CP configuration tool to establish an ISO 26262 ASIL-D functional safety framework. By implementing dual-core lockstep, redundancy checks, and fault degradation strategies, the project addressed the core challenge of balancing real-time control and safety mechanism resource utilization, achieving fault response times ≤10 ms. Aligned with the "three-in-one" protection requirements, ZC achieved deep integration of MCAL and the CP protocol stack, overcoming bottlenecks related to memory partition isolation and timing conflicts in communication encryption. Through over 100,000 fault injection tests, all specification requirements were fully met.

2. Breakthroughs in Key Technical ChallengesZC resolved conflicts between customized specifications and AUTOSAR standards, achieving the integrated "three-in-one" solution of MCAL, CP configuration, and functional safety for the TC366 chip. The project addressed the industry-wide contradiction between high safety levels (ASIL-D/ISO 21434) and low resource overhead in automotive embedded systems, limiting safety mechanism memory usage to ≤8 KB. ZC also overcame challenges in cross-standard compliance testing by building a dedicated verification system, achieving a fault detection coverage rate of 99.7%, exceeding industry averages by 30% in core metrics.

Project Highlights

1. Quantifiable Core Achievements: Efficiency MultipliedZC successfully reduced the development cycle by over 35%, providing a one-stop solution for specification adaptation, full-stack MCAL configuration for the TC366 chip, and VECTOR CP integration. This eliminated cross-stage debugging efforts for the customer and accelerated product mass production.

   Industry-Leading Safety Metrics: Achieved dual compliance with ASIL-D functional safety and ISO/SAE 21434 information security standards, with a fault detection coverage rate of 99.7%, fault response time ≤10 ms, and safety mechanism memory usage as low as 8 KB.

   Zero Compliance Rework: Achieved 100% compliance delivery by passing both customized specifications and international safety standards in a single validation, eliminating secondary remediation costs for the customer.

2. Key Service Advantages: Hassle-Free Partnership
   In this project, ZC deeply aligned with customized specifications and the multi-core characteristics of the TC366 chip, exclusively developing an integrated "MCAL + CP Configuration + Functional Safety" solution that required no additional coordination from the customer.

   End-to-End Support: Provided on-site support and rapid issue resolution (within 24 hours) from requirements analysis to test delivery, reducing the customer's technical trial-and-error risks.

   Lightweight Delivery: Delivered standardized configuration documents and a full set of compliance materials for direct reuse by the customer, minimizing subsequent maintenance costs.

3. Core Technical SupportZC pioneered the "three-in-one" integrated solution for the TC366 chip, striking a balance between high safety (ASIL-D) and low overhead. Core metrics exceeded industry averages by 30%, enabling the customer to "invest less, deploy faster, and achieve higher compliance."