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Zonal architecture and the future of vehicles

future of vehicles

Author: Greg Avery, Molex Strategy Development Manager

Innovation in the automotive industry has led to significant advances in vehicle functionality, spanning vehicle safety, performance and comfort. Some of these innovations come from the automotive industry itself, but others have been adopted from the motoring sector or the aerospace industry. A recent study co-sponsored by Molex and Mouser found that 43% of automotive professionals believe that one of the main drivers of future change in vehicles will be major technological advances in other areas that will enable new capabilities.

However, despite these advances in vehicle functions, the automotive manufacturing process has not changed substantially in decades. Electronic systems represent half the value of a new vehicle, but the technology used to connect the devices and control units has not kept up with advances in hardware and software. More than 57% of professionals surveyed in the study indicated that technology issues in manufacturing are a significant barrier to achieving a next-generation vehicle architecture.

The evolution of vehicle electronics design and vehicle manufacturing

Vehicle manufacturing has adopted highly automated production systems, which include extensive use of robots. This offers the benefit of consistent quality, as the robots perform repetitive tasks with excellent precision. However, some automotive components are not suitable for robotic manufacturing. Wire harnesses, for example, are flexible, and their lack of rigidity makes them difficult for robots to manipulate. In addition, due to the extensive network of power, data and control cables, the cabling system is complex and the installation of cable harnesses is complicated. Therefore, these harnesses are mostly assembled by hand, which is more expensive than automation and more prone to human error.

New functions and systems are added to modern vehicles through the installation of additional electronic control units (ECUs), with their associated wiring. Consequently, each new feature adds to the complexity of the wiring and electronics design. Newer vehicles can have between 100 and 150 ECUs each, along with complex wiring harnesses. Manufacturers have limited space to accommodate a vehicle's electronic system, and with the current approach, adding more functions and features will soon be out of reach.

At the same time, copper cables are heavy. The larger the cable infrastructure in a vehicle, the more the vehicle weighs, which is problematic in electric vehicles. Its design focuses on limiting weight to maximize driving distance on a single battery charge, which is crucial for consumer acceptance. Next-generation vehicles will also have greater demand for high-speed, reliable connectivity. This requirement is vital for communication between vehicles and the traffic control infrastructure, which is the foundation of autonomous driving.

Current cabling architecture solutions and their limitations

The current method of adding electronic equipment and features piece by piece has led to duplication of wiring with complex architecture. Flat cabling is of point-to-point design, which is the least efficient architecture in terms of cabling volume, assembly efficiency, and labor intensity. That type of architecture leads to a clutter of space, making it unsuitable for the additional features that the future of the automotive industry demands.

Many manufacturers have moved to a more structured cabling architecture, known as domain design. This method groups vehicle functions into domains that communicate with each other using gateways. The result is a complete vehicle system that encompasses the powertrain, safety systems and infotainment. Domain architecture is more flexible than a flat structure, but still falls short of the flexibility and efficiency needed for next-generation vehicles.

The automobiles of the future will be part of a dynamic network that encompasses vehicles and traffic control infrastructure. This capability is vital for autonomous vehicles, which will need to collect, analyze, and act on information about their environment with minimal delay. These cars will have more sensors, controls, and computing power than ever before. Manufacturers need a new cabling architecture that can accommodate these needs and take advantage of new technologies from other industries, such as 5G wireless communication.

The future of zoned vehicle wiring architecture

Designers use zonal architecture to organize a vehicle's wiring system like a computer network. They group vehicle functions into zones by location so devices are connected to their zone controller via the shortest possible path. Each zone controller is connected to the central computing cluster via a network cable, which offers significant advantages in terms of the number of cables and the speed of data transmission.

Vehicles equipped with zonal architecture will be able to take advantage of modern high-speed communication and computing power. The network will process data at speeds of 10 gigabits per second (Gbps) or more, and its computing power will be equivalent to some of the best desktop workstations. This speed of data transfer and computational power will be crucial to process the large amount of information from sensors required by Advanced Driver Assistance Systems (ADAS) and autonomous driving.

Using the shortest possible wiring path for each device reduces the total amount of wiring and therefore the weight of the vehicle. Replacing standard copper cables with network cables has a similar effect. Designers are working on models that are even more efficient by increasing the power of 12V devices to 48V so current draw is lower and wire gauges can be reduced. Reducing the load on the cables in an electric vehicle is a valuable contribution to improving battery life and customer satisfaction.

In the future, manufacturers will change features using software-based functionality, without the need to change the hardware infrastructure. This advancement, along with zoned architecture designs, will make it possible to simplify and standardize wire harnesses. The components for installation and immediate use (plug-and-play) will be easily added or replaced, making vehicle maintenance simpler and more accessible to standard garages.

Barriers to adopting a zonal cabling architecture

The automotive environment is harsh for sophisticated wiring and electronic systems. Atmospheric impacts, such as wind and rain, expose vehicles to high levels of humidity, in addition to dust and dirt from road surfaces. Even everyday driving exposes a car to levels of vibration and shock not found in other high-tech applications. However, the rigorous safety requirements for autonomous driving demand a high level of reliability of the devices, wiring, connectors and control units. Even a momentary interruption of the connection due to vibration can have disastrous consequences. Components and connectors for zoned architecture will need to meet the rigorous demands of this industry.

Changing regulations also affect the adoption of zonal cabling architecture and autonomous driving. USCAR regulations will need to be adapted to the US market, while Europe uses the LV214 standards. There is uncertainty as to how these regulations will change for new automotive technology and what direction the Chinese regulatory bodies will take. At the same time, consumer demand for electric vehicles will depend on the deployment of charging stations and 5G infrastructure.

The power of connection

Connector design will play a crucial role in the success of your zonal cabling architecture. A new generation of hybrid connectors that can transmit power and high-speed signals will be required to connect the devices with the zonal gateways. The connectors in the central computing cluster will also need to be robust enough to withstand the harsh conditions found on the road. For established manufacturers, adapting their current processes to meet future demands could present a challenge. However, they have the advantage of having an extensive resource base for developing new solutions. Emerging companies are more flexible and adaptable to change, allowing them to respond quickly to changes in market demand and new technological advances.

Moving away from manual processes in manufacturing and assembly is also appealing. Using rigid, standardized wire harnesses can help automate this aspect of vehicle assembly. Some manufacturers are developing suitable connectors for manipulation by robots. Designing connectors that meet the demands of the vehicle of the future, are compliant with regulations and suitable for robot manipulation could be a vital factor in the adoption of zonal architecture to support ADAS and autonomous systems.