Building a Scalable and Safe Platform-Level Encoder System for Automotive & Industrial Applications

AIsemi has successfully developed a platform-level Encoder System, ensuring high reliability, functional safety, and seamless integration across multiple hardware and software environments. Unlike ASIC-specific encoder implementations, this platform-level solution provides scalability, modularity, and cross-domain applicability, making it suitable for automotive, industrial automation, and robotics.

Project Overview

The Encoder System platform was designed to support various sensor interfaces, real-time signal processing, and fault-tolerant mechanisms. AIsemi’s expertise in hardware-software co-design, error detection, and safety assessment enabled the development of a high-performance and ASIL-compliant encoder solution that remains reliable throughout production, operation, service, and decommissioning phases.

Key Objectives

• Platform-Level Integration: Designed a scalable encoder system supporting multiple sensor types and communication interfaces (SPI, I2C, CAN).
• Functional Safety Compliance: Developed ASIL-C/D compliant safety mechanisms to ensure accurate position tracking and fault detection.
• Fault Detection & Redundancy: Implemented real-time error correction, redundancy, and fail-safe mechanisms.
• Lifecycle-Centric Work Products: Ensured safety across production, operation, service, and decommissioning phases.
• Latency Optimization: Ensured real-time data acquisition and high-speed signal processing for safety-critical applications.

Technical Approach

• Multi-Sensor Support: Integrated optical, magnetic, and capacitive encoders within a unified processing architecture.
• FMEDA for Safety & Reliability: Analyzed potential failure modes, diagnostic coverage, and failure rates to enhance system robustness.
• Error Detection & Correction: Implemented CRC-based validation, self-test mechanisms, and signal integrity monitoring.
• Scalable Hardware & Firmware: Developed a platform-independent firmware stack enabling seamless portability across multiple SoCs and microcontrollers.
• Validation & Compliance: Verified platform behavior through fault injection testing, real-world simulations, and ISO 26262-aligned V&V processes.

Lifecycle Work Products & Activities

Production Phase

• Manufacturing Process Documentation: Ensured functional safety compliance in hardware production.
• End-of-Line (EOL) Testing: Implemented safety validation tests for each encoder unit before deployment.
• Safety-Related Work Instructions: Provided detailed guidelines for production teams to maintain functional safety integrity.

Operation Phase

• In-Field Safety Monitoring: Developed diagnostic and self-check routines for continuous operation.
• Fault Reporting & Safety Warnings: Implemented real-time error logging and reporting mechanisms.
• Software & Firmware Updates: Ensured safe deployment of patches and security updates without compromising performance.

Service Phase

• Maintenance Procedures & Diagnostics: Provided troubleshooting work products for field engineers.
• Service Manuals & Safety Guidelines: Developed detailed service documentation ensuring compliance with ISO 26262 maintenance requirements.
• Replacement & Repair Workflows: Standardized safe component replacement strategies to maintain encoder reliability.

Decommissioning Phase

• Safe Decommissioning Procedures: Established controlled shutdown and disposal methods for encoder systems.
• Data Logging & Traceability Reports: Maintained records for safety audits and compliance verification.
• Environmental Compliance: Ensured decommissioning aligns with recycling and disposal standards in regulated industries.

Outcome & Impact

• Cross-Platform Compatibility: Enabled seamless integration across automotive, industrial automation, and robotic systems.
• Enhanced Safety & Reliability: Improved fault tolerance and diagnostic coverage for encoder-based applications.
• Optimized Performance: Achieved low-latency, high-speed position tracking with minimal error margins.
• Regulatory Compliance: Ensured full compliance with ISO 26262 (ASIL-C/D) and IEC 61508 safety standards throughout all lifecycle phases.

Conclusion

By developing a platform-level Encoder System, AIsemi has delivered a scalable, reliable, and safety-compliant solution for automotive, industrial, and robotic applications. Our lifecycle-focused approach ensures functional safety across production, operation, service, and decommissioning, allowing seamless integration into next-generation safety-critical systems.

Stay tuned for more industry-specific use cases showcasing AIsemi’s expertise in functional safety, semiconductor validation, and safety-critical platform design!