This content provides an overview of automotive architecture, focusing on the evolution from traditional ECUs to domain controllers and zonal architectures, with a particular emphasis on the power electronics and silicon components crucial for electric vehicles (EVs).
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Hello guys. Hello. Hello. Yes.
Yes. So
So
mobile you can see here only. Fine. Okay.
Hello guys. Hello. Hello.
I'm Bajira. [clears throat]
Today I am your instructor for the day.
And today we are going to learn about uh
this automotive architecture because
like this EV EV whatever you have
learned till today like it comes under
automotive. Okay. So it's a it's a part
of automotive only. So understanding of
the automotive architecture is very much
important. So as you know like you have
already learned about batteries, motors
and how the power train works. Uh Punar
has thought all these things if I'm not
wrong. Right. Yeah. So now we are going
to learn about the automotive
architecture where like the architecture
starts with starts with the uh the first
layer like that comes is microcontroller
that is MCU. You can see it over here.
So MCU is the first basic part because
the without the controller you can't
deal with any of the functionality of
the vehicle. Okay. So controller plays
the major part. So you you can you can
write it down if you want. Okay. So MCU
is the major part. So where the
controller is kept. Okay.
Then comes the basic software layer that
is S uh BW.
In that BSW
you have three layers. One is service
layer. The second layer is ECU
abstraction layer and the third layer is
microcontroller abstraction layer.
Okay. The controller which we are
talking like might be STDM, Infinion,
NXP, any of these boards are called as
microcontrollers. Okay. The controlling
part that will be done by the coding
whatever the code you are dumping into
the controller that is called as
microcontrol abstraction layer. Okay.
ECU also comes in the same way like you
you can see like in the BW layer you
have three layers. The service layer
will will help you to enter into enter
into ECU abstraction layer. Okay. And
this complex device driver is nothing
but CDDs. These drivers will help you to
connect between the MCU and the
application layer because it it is the
in between layer where the application
layer will call through autosar uh
runtime environment that is RT. So RT
when when you are calling the
application from the application layer
it will it will come to the complex
device driver where it where it will
call the function. So that function will
be called then the application will be
happening that the performance it will
perform the action like whatever the
application layer is exe uh tell to
So as you can see here there is a
traction motor placed here. Okay. So
motor is what what is the how many types
of motor you have learned till now. This
is actually like the four-wheer setup.
If you are considering two wheel setup
also there also the motor is motor is
visible. How many types of motor you
have uh seen? You can comment in the uh
you can uh tell them tell that in the
So power distribution unit is also
there. Then traction inverter onboard
charger. What is the major component in
the EV that is battery right? So here we
are using battery as a source where like
it is charged by a DC toDC converter
because the supply which we are giving
is AC. So whatever the supply you are
going to give that will be converted. So
that is stored in a battery. So battery
stores in DC. Okay. So it's it won't be
in AC. So DC is the uh main source like
where the charge is stored. So that DC
is uh transmitted to the motor with the
help of BMS. Without the BMS like if you
transfer directly the battery voltage or
something. So it it might be harmful for
the motor and like there are chances of
like uh getting fire or something. Okay.
So all these things you can see like in
the architecture of electric vehicle
architecture also this has been
explained by Puniter if I'm not wrong.
But as you're learning this automotive
architecture, so parallelly learning of
the electric vehicle architecture is
also important. Next,
so as you can see here also the battery
is nothing but the chemical energy where
like the battery is converted like the
auxiliary power is also provided by the
battery only because the battery pack
which you will be using of higher
capacity. It might be 72 volts like uh
42 48 volts or some more than that only.
But the auxiliary power like which you
are using for headlight indicators or
something like it it it needs only like
small power consumption. It won't be of
that high voltage. So auxiliary power
battery we need it like to convert that
like again we'll use buck converter. So
if you heard of power electronics like
in the power electronics part there are
converters where like DC toDC conversion
is happening. In the DC toDC converters
you will study about this buck converter
where the buck converters helps you to
convert from higher higher voltage to
lower voltage. So auxilary battery like
if you're connecting from the main
battery you you will use the buck
converter to convert the higher voltage
to into the lower voltage. Okay. And
again from the battery you will
providing it to the motor controller
because without uh like supplying the
voltage to the uh if you want to supply
the voltage into the motor pass the
voltage or current whatever. So at that
So from battery you are supplying it to
the motor through the motor controller
or the vehicle control unit. So from
that you you you can like supply the
power to the motor. Okay. So motor like
there are like two losses in that also
you can see IR square losses and the ED
current loss. So there there will be
heat also like there are transmission
losses like there are many losses like
that comes to the picture here. So this
all affects in the uh this one u
efficiency of the vehicle. Okay. The
mileage will be less compared to the
other vehicle if the losses are more. Okay.
Okay.
So now we are going to learn like what
what is domain controllers because like
if you if you have known about the
microcontroller then comes the ECUs then
like there are specific domain
controllers as well. The nervous system
of the modern vehicle are the like
domain controllers.
So as you can see the controller is the
uh it it converts the energy like where
like transferring of the energy can be
So during 1990s and 2000 like the wiring
system like whatever the wires connected
to the to transfer the power like it's a
whole mess like you can see the wirings
from wherever it is going from 1990s to
2000 the distribution was happening in
some other way. So this is how it looks
like the ECUs are connected from uh one
point to another point and the wiring is
connected like it's a whole mess you can
see because like if something goes wrong
in a vehicle so you can't find out like
where the where it is happening okay so
that is the reason and in early 20ou
2010 during that time this uh domain
controllers were introduced so from ECUs
like uh like you can see the CAN if you
heard of CAN communication so that is
executed in
this one uh vehicles actually. Okay. So
now at present after like 2020s uh so
the future like u they are using
centralized uh this thing like uh ECUs
like you you are connecting only four
domain ECUs that will help you to uh
communicate between the uh vehicle
So what do you know by what you know
about like the microcontroller? How many
types of controllers you have used in
Okay. So if if you use of Ardino or
something 8051 if you have heard of it
like like those controllers are not used
in in traditional like in the industries
right now. So they are using ECUs like
you can see like how how it commutes
like the power power what is transmitted
and the safety and the connectivity. Uh
previously the traditional ECUs used to
have like low range actually. So low
range MCUs which are single core. Now
like in the domain controllers you can
see like there are high performance
SOC's like multi-core. Multiore is
nothing but like from one core to
another core like u the transmission of
the this one like data will be happening
from one core to another core. So
isolated power uh we are using in the
traditional ECUs but here we can use the
shared power. So that can be used by PM
PMIC. So that I'll explain later. So
from the safety part like uh safety per
ECUs is is different. So we are using
ASIL that is like B2D domain concepts
here. So the connectivity previously
that they are using in the traditional
ECUs are CAN because in early 2000 2000s
and 2010s the CAN can CAN communication
was introduced. So they were using CAN.
So for now like in 2020s after 2020s
like they are using the domain
controllers DCUS. So you can see like uh
they are using gigabit or ethernet. Even
the CAN FD is the extended part of the
CAN only but like it's a fixed data
So like there are five functional
domains. The major part of the electric
vehicle is the power train like which we
can call it as a heart of the EV. Okay.
So engine or the motor like we are using
like here we'll use only motors only.
So motor we are using. So motor and the
transmission BMS BMS is nothing but
battery management system. Then again
hard realtime constraints this all
things will come come in the powertrain
concept and again like without chassis
like without mechanical people the
chassis can't be done. So many
mechanical students are here. So yeah uh
chassis are like steering, braking,
suspension and high safety criticals
like everything will be done uh with the
help of mechanical engineers over here. Okay.
Okay.
So then comes like the ADAS system
because like without ADA system
automatic driving this thing. So radar
later like all the sensor part will come
because without using sensors if
something impact happens then like the
airbag will not open then the person
will die that is for sure. Okay. So ad
system is very much important. So then
comes the infotainment system where
multimedia because without music you
guys won't travel in car. So you need
music system and now you have used uh
introduced that in the Ola also to to
enjoy the music and to have a ride on
the bike also you have multimedia over
there also and navigation V2 uh V2X and
high data throughout like will be it all
it all comes under infotainment system. >> [clears throat]
>> So now we'll come to the domain
controller where the hardware core like
it you can see in the screen. So where
you are using like SOC SOC is like uh
system uh charge you can uh you can say
like but here like SOC is different.
This is system on chip actually. Okay.
So PMIC as as I was discussed pre as I
told previously that is nothing but
power management IC. So IC's are nothing
but like they are the controllers
actually where like you can regulate the
power from 0.8 volt to 5 volt like
minimal amount of voltage is provided
for the uh PMIC to get get it uh get it
connected like if you want to dump
something so you need a like
connectivity. So that connectivity will
be given from PMIC. Okay. So then the
SOC the system on chip there are
multiore like multi-core ARM cortex AR
like nothing but like single core were
used previously. So in the domain
controllers they are using the multiore
thing the ARM cortex they are using. So
GPUs DSPs and and this is this is
nothing but a brain of the system you
can say because without this like the
vehicle can't understand whatever the
functionality or whatever the input you
are giving. So you you you won't get to
know like you have to give the input. If
you're pressing accelerator it should go
to the vehicle control unit where the
SOC is introduced there like uh if
you're passing some uh if you're giving
acceleration it should get to notify
like the person wants to accelerate from
from 40 km to 60 km some something. So
the input is given to the SOC chip that
will communicate it to the MCUs the
motor control unit. From there the motor
will be given like the motor will run in
a speed like a much faster way. So this
is how works in SOC and that that then
comes the hardware security model that
is encrypted uh board and key storage
that that you are using ISO 214434.
Even we have a safety standard protocol
that is ISO 26262. Actually you can go
through that also in future because like
that is used in the automotive domain uh
in most of the parts because without
safety guidelines you can't execute any
of the vehicle like uh you can you can't
you can't prepare anything without the
safety guidelines. So that is also
important and the connectivity they are
given here like the CAN FD and the
flexays and transceivers here they are using
So now we'll see like how IC and the uh
this EV power train is differentiated.
Okay. So in IC's we have engines
actually four strokes engine six stroke
engine like we have multiple and there
are many moving parts in it. Okay.
Hundreds of moving parts and there there
will be a multi-gear transmission also.
So multi-geear transmission is happening
in the ice. So if you shift the gear
from first gear to second gear or second
to third gear that then you can increase
the speed but all these things are not
there in this EVs actually if whatever
the throttle you are giving so it it
won't be dependent on any of the other
things. So how much of the throttle you
give that much speed you will get in the EVs.
EVs.
So torque and other things you can see
it in internal combustion engine that is
ice. But in EVs like there are only like
majorly you can consider three three you
can consider. One is battery. So which
is a DC source which will help in
providing the supply to the motor and
again the power things comes here. The
inverters in introduced because if the
motor is AC so if the motor is AC to
transmit the DC DC to AC there there
should be a conversion happen. So
converter we are using so from in uh so
so convert in converter part we are
using here inverter which will help you
to convert from DC to AC because like if
you're passing three-phase supply to the
motor you need to convert it. So you
here you are using the inverter
so the battery will be storing the
chemical energy and the major advantage
of the EVs are like there are less
moving parts. You can see like there are
hundreds of moving parts in ice but you
have like lesser moving parts like 60%
of the fewer moving parts compared to
So now we'll enter into the major part
like what are the power electrons which
we have discussed. So when when you when
it comes to the charging so the major
part is like the major place part will
be taken by the uh this one only power
electrons only. So there you are the OBC
like OBC is nothing but the onboard
charger. So where you are using DC toDC
conversion. Okay. So in the in the chip
also like you can uh from the domain
domain this one ECU also you can help it
out like you can pass the data like you
can transmit the power from higher
energy to lower energy or like to charge
the battery. So using the DC2DC system
here. So the integrated power box that
is nothing but the onboard charger that
is OBC. So from the grid supply you will
passing it to the battery. So battery
will be DC. So again here the conversion
from AC to DC that is nothing but a
rectifier. Okay. So there also the power
part will come. So HV and LV. How many
electronic electrical and electronic
students are there? Here you can say
like what is HV and LV?
>> So that is the basic. Okay. So high
voltage and low voltage you are
transferring here from the DC toDC
conversion. If you want to step up then
you will use the uh buck converter.
If you want to reduce from higher
voltage to the lower voltage there you
are using 48 volt to like 12 volt like
you can reduce the supply for the
auxilary battery and 5 kilowatt per L is
written. What what do you mean by L
here? Don't say liter. It's not
literally. Okay. So it is load actually.
So the efficiency which comes is shared
through the thermal management and the
capacity like capability is birectional
V2J and V2L. So that these things you
have learned from Punit like he has
>> because I I can't see here. Okay,
so now like we will introduce the
circuits like what are the circuits used
in the conversion. Okay. So in onboard
charger so if you if you know about
power electronics you might have seen
half bridge full bridge like circuits.
Okay. So the PMIC PF uh PFC stays like a
bridgeless totem pole like this. This is
one of the circuit where the AC supply
is uh introduced like you you are
passing the AC supply into the inductor.
Again it's given to the MOSFET that that
here they are using four MOSFET that is
Q1, Q2, Q3 and Q4. So they are highly
efficient and reduces the conduction
losses because to switching is more like
highly efficient here. So you're using
MOSFETs. So where the load is DC. So
you're transmitting from AC to DC. So
that is the rectification process is
happening here.
So again from DC to DC you will step up
it using the buck converter. So you will
transfer the power like you can you can
boost the power. So you can transmit it
into a transformer. Then again from
diode like you're passing the voltage
because like if you directly pass the
voltage. So the there are high chances
like the vehicle like motor winding may
lose like uh uh the properties will like
losses will be more. So you are
transmitting the power like from in from
using this diode like you will transmit
in like lower capacity. Okay. Then this
birectional dual active bridge will come
that is nothing but DAB where like
you're connecting DC to DC like
conversion is happening here also. So
like four MOSFETs are in the uh left
side and four MOSFETs are in the right
side. So this this circuit you can
implement in the MATLAB simulink as well
So how many challen like challenges are
there like using for this sick MOSFET
also like six sick thing also. So
mastering wide band gate that is sick
paralleling. So the problem statement
here is like paralleling sig MOSFETs
causes current imbalance due to
threshold wtage that is VTH is nothing
but the threshold wtage.
Okay. The solution is like the precise
binning like that is nothing but the
tolerance power is less here like you
can see like less than 1.2 voltage they
are using. So the solution is like you
can use the this one calvin source con
connection to like reduce the power
supply like you can give less than one
one one nano herz uh Henry here here
they're saying like because like the
inductance capacity is comparatively
less so decoupling gate loop they're
So the second challenge which we are
going to see in sigmos suits is like
gate driving protection where you can
see like what is mean by WDD V. So all
these things you guys might have learned
in this one. Um uh opamp opamp opamp right
right
>> opamp only. Yeah. So WD and V. So in and
out like you can see in the great driver
IC. So IC you might have used in the
labs. So th those things only be used in
the industries. So you can like if you
know much about opamp or something like
you can enter the industry. So design to
these circuits are like how to implement
these things you can you can check it
over there. And active clamping against
the voltage spike is nothing but uh the
we are using birectional thing like
where you are transferring the power
like whatever the output is coming
you're transferring it to the gate and
So challenges that is signal integrity
and isolation signal chain like you can
see uh you can see here where the MCU is
like 3.3 volt they are using using like
to give the supply. So it is birectional.
So it is birectional trans uh
translation where the level shifter is
used. So level shifter is nothing but
like you can use from like higher lower
voltage to higher voltage you can shift
the level. So to for uh that will that
will be transmitted into the digital
isolator. So from there you will provide
it to the gate driver which which is
again like isolated by a supply. You can
transfer the power through the gate
driver and that will be provided to the
sigmoset which is having the higher
capacity like as they have written like
here the sigmos like it can consume up
and the last challenge like efficiency
in the low voltage. Okay. So active
rectification is happening here. So
there are high losses if you are using
this diode normal diode. If you use then
the like there are high chances of high
high loss of voltage like the diode
might be might get like burnt or
something. So you are using here the
ideal diode like with nearer to zero
losses because if you use diode the
losses are more. So in
ideal diodes the losses are
comparatively less. So as you can see
like how the sigoset like the chip like
inside the chip. So this is how it is designed.
designed.
So from copper clip topology that is LF
pack or CFP
okay replaces the wire bond for for
superior thermal dissipation and low
lower resistance by transferring like
so by transferring this using this like
u copper clip you can you can transmit
So you can see the zonal architecture
here. So where the uh you can see the
front and rear wheels. So there like in
the front left zone they are using jet
brain mono like that that is also like
used in the this one also like rear zone
also similar kind of thing. So benefits
of using the doing doing this is like
the weight distribution will be proper.
So wait like copper cabling like reduces
by 50%. If you are using u how much like
three if it if it can give 3 kilometers
like if you connect it in both the ways
then it will be the kilometers will be
like 1.5 km it will be so manufacturing
thing like there are automated
harnessing assembly because like the
without the harness you can transmit any
any of the voltages or something. So to
transmit voltage or current the wiring
harness plays the major role. So wiring
harness is the important part again.
So reliances like localized power
distribution and fail shapes like if the
wiring harness is not proper there are
high chances of um like the vehicle
getting into fire like there are high
So overall summary like what we have
learned like till now is the vehicle
architectural velocity like uh this
distribution like how the domain ECUs
are used. So how it is converted into
zonal so driven by weight reduction and
software defined features. So
architecture uh this velocity all these
things comes under this architecture
only and integration is it is nothing
but the power box where like the power
electronics like things are used like
OBC comes under power electronics and DC
toDC conversion is also comes under
power electronics. So is the new
standard for density from vehicle to
grid. So that is the capability and the
silicon uh key which we are using the
sik MOSFET which we are using here is
like 800 volts uh demands S uh GAN
success requires precises gate driver.
So negative bias and detect we are using
in uh S key components that we are using is
is
reliability. So that is energized at the
micro level, Kelvin sources, uh copper
clips and robust isolation. So all these
things we have learned till now. So and
now like Yusur and Nikil sir will join
us and uh to show us in the um like what
is happening in VTO Nagar and how many
students are attending in VTO Pagabi. So
we'll we'll get back to you guys in next
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