Introduction
The fast adoption of electric cars (EVs) is causing a seismic shift in the global automotive surroundings. 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 perform this role.
Function: Controls the temperature within the cabin using low-voltage electronics, even if the high-voltage system may still be used to power the compressor.
5. Braking and Power Steering Assistance
Its function is to supply power assistance for braking and steering.
Function: To ensure ease of handling, low-voltage electric motors are used 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.
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.
Function: 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 are designed to handle specific duties for each other, which enables fault isolation and more efficient data delivery. The many CAN networks that are frequently seen in EVs are summarized as follows:
1. Powertrain CAN
Establishes communication between the electric powertrain’s parts.
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 guaranteeing peak performance.
Provides real-time data interchange for motor control, energy management, torque requirements, and battery status.
2. CAN Chassis
oversees communications regarding vehicle dynamics and safety systems?
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 preserves the stability and safety of the vehicle.
3. Battery CAN Network
The Battery CAN Network’s mission is to oversee and control batteries.
Key Components:
Temperature, voltage, and current battery sensors are part of the battery management system (BMS).
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
Controls the temperature in the cabin and operates the HVAC system.
Key Components:
HVAC Control Unit
Temperature sensors for electric compressors and heat pumps
Functions: The interior climate control of the car is effectively ensured by this network. It controls how the seat heaters, defrosters, and cabin heating and cooling systems interact. This data is separated on a separate CAN network to avoid interfering with important driving systems.
5. Charging CAN Network
Function: Managing correspondence between the car’s internal charging infrastructure and external charging outlets.
Key Components:
Port Control Unit for Charging On-Board Charger (OBC)
External Charging Station Interface
The management of communication between the vehicle and the charging infrastructure is the sole purpose of this network. 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. It is the foundation of the electric car revolution, making sure that the promise of more intelligent, efficient, and environmentally friendly mobility is realized.
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