Introduction
The fast adoption of electric cars (EVs) is causing a seismic shift in the global automotive environment. Electrification is being embraced by governments and industry globally as a means of reducing transportation’s negative environmental effects and decreasing dependency on fossil fuels. EV System Integration is one of the most important and challenging aspects of this shift as EVs become more common. The performance, credibility, and efficiency of an electric car depend on the seamless integration of its numerous parts, which range from software and charging infrastructure to battery systems and power electronics.
This blog explores the future of this developing field as well as the significance of EV System Integration for electric vehicles and the essential elements that go into it.
EV System Integration is divided into three main Components:
1. High Voltage Components
2. Low Voltage Components
3. Multiple CAN Networks
High Voltage Components
High-voltage components are found in both hybrid and all-electric vehicles. High-voltage components are directly connected to the power battery in pure electric vehicles.
Battery packs or fuel cells, battery management systems (BMS), electric motors, motor control units (MCU), power distribution units (PDU), electric air conditioning compressors, DC/DC converters, on-board chargers (OBC), EV chargers, charging outlets, PTC heaters, and high-voltage wiring harnesses are some of the most common examples of high-voltage component.
1. Battery Management System (BMS):
Also known as the battery controller, the BMS is the essential component of battery management and protection. Its duties include monitoring the charging and draining of battery packs, assuring the safe and dependable usage of EV batteries, and providing the vehicle control unit (VCU) with basic parameter and fault diagnosis data.
Currently, the normal working voltage of electric car battery systems is between 200 and 600 volts. Additionally, its output current is 500A. EV driving range is directly impacted by battery capacity, which also influences charging time and efficiency.
Lithium-ion batteries currently rule the global market. Since lithium-ion battery technology is limited at this time, most electric automobiles employ them. Meanwhile, high-voltage electric vehicle systems use shielding design to lessen electromagnetic radiation produced by high-voltage components.
2. Motor control unit (MCU):
To move the automobile, the electric motor transforms electrical energy from the battery into mechanical energy. When compared to fuel-powered cars, which transform the chemical energy of fuel combustion into mechanical energy, it has a better operational efficiency (more than 85%). As a result, EVs have a higher energy usage rate than conventional cars. It can cut down on resource waste to a large degree.
A motor controller is a device that controls the flow of energy from the battery to the drive motor. Vehicle advance (motor revolving in a forward direction), vehicle reverse (motor rotating in the opposite direction), DC/AC conversion, and other operations are among its primary duties. It achieves effective control to operate the motor by converting high voltage direct current to alternating current and interacting with other modules of the electric car through signals.
3. Power Distribution Unit (PDU):
A PDU distributes high-voltage electricity throughout the vehicle in a manner akin to that of an electrical fuse box in a low-voltage circuit system.
To achieve signal communication and guarantee the safety of high-voltage electricity, it comprises several relays, fuses, and associated chips.
High-voltage electrical equipment, including motor controllers, drive motors, electric air conditioner compressors, PTC heaters, and DC-DC converters, are powered by high-voltage battery distribution. A high-voltage charging current is distributed to the battery pack simultaneously from the AC or DC charging connector to charge it.
4. ON Board Charging:
An OBC is a device that converts alternating current into direct current. When using alternating current for charging, the battery pack cannot directly store the alternating current because it is a high-voltage direct current power supply. A high-voltage AC to DC converter known as an OBC device is needed to charge the battery.
5. DC/DC Converter:
A device known as a DC/DC converter changes direct current from high voltage to low voltage. Electric cars lack an engine and use power battery packs and storage batteries instead of generators and storage batteries to power the entire vehicle. To keep the overall power consumption of the car balanced, a DC/DC device is needed to convert high voltage DC to low voltage DC since the electrical equipment on electric vehicles is often powered by low voltage 12V or 24V.
Certain DC/DCs convert high voltage to high voltage to support three things:
1) fast charging,
2) connection to standard charging stations,
3) BMS dependability.
6. Electric AC Compressor:
The moving scroll, fixed scroll, support bracket, anti-rotation mechanism, radial flexible mechanism, electric motor, and inverter electric control portion make up the electric AC compressor for an electric automobile air conditioner. It is the basis of the air conditioning system in electric vehicles. Its benefits include a lightweight, steady operation, low noise, simple structure, and high efficiency.
7. PTC Heater:
The coolant that is injected into the engine after cooling provides the heat source for the conventional car HVAC system; this coolant is absent from new energy vehicles. As a result, a unique heating apparatus is needed. PTC heater is the name of the gadget. When the outside temperature drops sufficiently, the battery pack requires a specific quantity of heat to function properly. The battery pack is now being preheated using a PTC heater.
Modern e-compressor technology is developing at a rapid pace, leading to the development of innovative, highly efficient heat pumps that are used to warm car interiors.
Low Voltage Components:
Low-voltage parts of an electric vehicle (EV) run independently of the high-voltage battery system that powers the electric motor, often on a 12V or 48V electrical system. These low-voltage parts are necessary for the car’s different support systems. The primary low-voltage parts of an EV are as follows:
1. 12V Battery
provides power to low-voltage electronics, such as lighting, control, and entertainment systems.
Function: Supplies power to these components even when the high-voltage system is off by acting as a buffer.
2. Lighting System
Headlights, tail lights, and interior lights
operate on a 12V electrical system and provide interior comfort and driving illumination.
3. Information Display System
Contains GPS, radios, touchscreens, and other multimedia interfaces for its intended use.
Function: It manages user interactions and media entertainment and is powered by low-voltage technology.
4. Controls for HVAC Systems
HVAC (heating, ventilation, and air conditioning) controls and displays play a crucial role in maintaining cabin comfort and air quality. Moreover, they allow passengers to adjust temperature, airflow, and ventilation settings with ease. As a result, the driving experience becomes more comfortable and energy-efficient.
Function:Low-voltage electronics control the temperature within the cabin, even if the system may still use the high-voltage power to operate the compressor.
5. Braking and Power Steering Assistance
Its function is to supply power assistance for braking and steering, ensuring smoother and more responsive vehicle control. Furthermore, this assistance reduces driver effort, enhances safety, and improves overall driving comfort. As a result, the vehicle remains stable and easier to maneuver, especially in critical situations.
Function: To ensure ease of handling, we use low-voltage electric motors to increase the driver’s input effort.
6. Cooling Fans and Pumps
Its purpose is to control the cooling of a few low-power parts, such as auxiliary systems and some electronics, ensuring optimal performance and longevity. Moreover, proper cooling helps prevent overheating, which can lead to system malfunctions. As a result, the overall efficiency and reliability of the vehicle’s electronic components are significantly improved.
- Function: Low voltage power source keeps systems within operating temperature ranges.
7. Power Windows, Wiper Motors, and Additional Comfort Systems
Manage vital car components including the wipers, seats, and windows.
- Function: Low voltage power supply ensures safe and convenient operation.
8. Instrument Cluster and Dashboard Displays
- Function: Offers car data such as range, battery level, speed, and navigation.
- Provides the driver with real-time data by running on low-voltage electricity.
9. Vehicle Control Unit (VCU):
The Vehicle Control Unit, also known as the “brain” of an electric vehicle (EV), functions as the main controller. It is essential to make sure that the electric powertrain, battery management system (BMS), and power electronics, among other various EV subsystems, all function as a unit. The vehicle’s central processing unit (VCU) gathers, processes, and transmits commands to different actuators to control operations including energy regeneration, braking, acceleration, and battery management.
Multiple CAN Networks
Multiple Controller Area Network (CAN) buses are frequently utilized in contemporary electric cars (EVs) to handle the intricate communication requirements between different Vehicle control units (VCUs) and other components. For dependable, real-time communication between the many systems in the car, CAN networks are essential. CAN networks handle specific duties for each other, enabling fault isolation and more efficient data delivery. The many CAN networks that are frequently seen in EVs are summarized as follows:
1. Powertrain CAN
The system efficiently establishes communication between the electric powertrain’s parts, ensuring seamless data exchange and coordination. Moreover, this connectivity optimizes power distribution, enhances efficiency, and improves overall vehicle performance. As a result, the electric powertrain operates more smoothly, delivering a reliable and responsive driving experience.
Key Components:
- Battery Management System (BMS): Keeps an eye on and regulates battery safety, charging, and performance.
- Motor controllers and inverters: Manage the power supply and regenerative braking of the electric motor.
The Vehicle Control Unit (VCU) is in charge of managing the complete powertrain system and ensuring peak performance. Additionally, it provides real-time data exchange for motor control, energy management, torque requirements, and battery status. As a result, the vehicle operates efficiently, with optimized power distribution and enhanced driving dynamics.
2. CAN Chassis
The system effectively oversees communications regarding vehicle dynamics and safety systems, ensuring seamless coordination between critical components. Moreover, it enables real-time data exchange, which enhances vehicle stability, responsiveness, and overall safety. As a result, drivers experience improved control, while advanced safety features operate more efficiently.
Key Components:
- The Anti-lock Braking System (ABS) regulates brakes and keeps track of wheel speed to keep wheels from locking up.
- Electronic Stability Control (ESC) keeps the car stable by controlling brake force distribution and engine power.
- The power steering system regulates and provides feedback for electric power steering.
Function:
By coordinating sensors and actuators connected to the suspension, steering, and braking systems, it effectively preserves the stability and safety of the vehicle. Moreover, this coordination allows for real-time adjustments, enhancing overall performance. As a result, drivers experience improved handling, reduced risk of accidents, and a smoother ride.
3. Battery CAN Network
The Battery CAN Network’s mission is to oversee and control batteries, ensuring optimal performance and safety. Moreover, it facilitates real-time monitoring and communication between battery components. As a result, it helps enhance efficiency, extend battery life, and improve overall vehicle reliability.
Key Components:
Temperature, voltage, and current battery sensors are integral components of the battery management system (BMS), as they help monitor and regulate battery performance. Additionally, these sensors ensure safe operation by detecting potential issues such as overheating or voltage imbalances. As a result, the BMS can optimize energy efficiency, extend battery lifespan, and enhance overall vehicle safety.
Functions:
The battery pack’s optimal operation is the responsibility of this CAN network. It controls the flow of data about diagnostics, thermal regulation, charging status, battery health, and cell balancing. To avoid overcharging, overheating, or any other problems that can compromise performance or safety, the network continuously checks on the battery.
4. HVAC CAN Network
In addition to ensuring passenger comfort, the system also controls the temperature in the cabin and operates the HVAC system. Furthermore, maintaining an optimal climate inside the vehicle enhances energy efficiency and overall driving experience. As a result, a well-functioning HVAC system contributes to both comfort and battery performance in electric vehicles.
Key Components:
- HVAC Control Unit
- Temperature sensors for electric compressors and heat pumps
Functions:
This network efficiently ensures the interior climate control of the car, allowing for precise temperature regulation. Specifically, it controls how the seat heaters, defrosters, and cabin heating and cooling systems interact, ensuring passenger comfort in various conditions. Furthermore, we separate this data on a dedicated CAN network to prevent interference with important driving systems. As a result, vehicle safety and operational efficiency remain uncompromised.
5. Charging CAN Network
Function:
Managing correspondence between the car’s internal charging infrastructure and external charging outlets is essential for ensuring efficient and reliable charging. Additionally, seamless communication between these systems enhances charging speed, safety, and user convenience. Furthermore, effective integration helps prevent compatibility issues and optimizes energy transfer. As a result, EV owners can enjoy a more reliable and hassle-free charging experience.
Key Components:
- Port Control Unit for Charging On-Board Charger (OBC)
- External Charging Station Interface
The primary purpose of this network is the management of communication between the vehicle and the charging infrastructure, ensuring seamless data exchange. Moreover, this communication allows for efficient charging, real-time monitoring, and enhanced safety. As a result, the charging process becomes more reliable and optimized for both performance and convenience. To provide safe and effective charging, it controls voltage and current, monitors charging status, and organizes the flow of electricity during charging. For instance, it makes sure the battery gets the right amount of power during fast charging so it doesn’t overheat or sustain damage.
Conclusion
An essential component of the shift to electric mobility is the integration of electric vehicle systems. It goes beyond simply putting different parts together; it also involves making sure they function effectively, safely, and sustainably as a whole. The EV System Integration issues will persist in their evolution along with the growth in EV adoption, and the corresponding technologies and processes will also change. The future of EV system integration promises to uncover even greater possibilities for electric vehicles, influencing the development of energy and transportation systems, thanks to advancements in batteries, power electronics, and software.
It is impossible to overestimate the significance of smooth EV system integration as the globe continues to move toward cleaner and more sustainable modes of transportation. In this context, ensuring seamless compatibility between various EV components becomes crucial. Moreover, a well-integrated system enhances efficiency, safety, and overall user experience. Therefore, businesses and engineers must prioritize robust integration strategies to drive the future of electric mobility.
“Empowering your EV solutions with high-performance VCUs, cutting-edge CAN keypads, versatile CAN displays, and innovative EV software services – driving efficiency, connectivity, and reliability into every journey.” Connect with us @ info@dorleco.com