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In this article, we explore the critical role of Vehicle Control Units (VCUs) in the EV powertrain. As the central management systems within EVs, VCUs oversee and regulate essential functions like motor management, battery supervision, and energy efficiency. Additionally, the article will discuss the communication protocols that allow VCUs to seamlessly integrate with other vehicle systems, enhancing the overall vehicle performance and efficiency.
The automotive industry is at a pivotal point in its history, marked by the rapid ascent of electric vehicles (EVs) and the decline of traditional internal combustion engines (ICE). This seismic shift is not just a change in the type of energy used to power vehicles but also a transformation in how vehicles themselves are conceptualized, designed, and integrated with the broader technological ecosystem. Central to this transformative era is the advent and development of Vehicle Control Units (VCUs).
A vehicle control unit is an electronic device in EVs, which serves as the brain of the vehicle's electrical system, overseeing and regulating various subsystems, including the motor drive, battery management, thermal management, and energy regeneration systems, to ensure they operate efficiently and harmoniously. The VCU also facilitates communication between different vehicle components, supports diagnostic and safety functions, and can integrate with advanced driver-assistance systems (ADAS). The vehicle control unit is crucial for the overall performance, safety, and energy efficiency of the vehicle.
A VCU can be labelled as the technological controlling module of modern EVs, similar to the central processing unit (CPU) of a computer. In the same way that a CPU oversees and controls the various functions of a computer, a VCU manages and harmonizes the multitude of electronic systems and subunits within an electric vehicle.
Inside a VCU, you will find a microcontroller that acts as the central nervous system, processing data from various vehicle sensors and executing control algorithms. It also contains analog-to-digital converters (ADCs) and digital-to-analog converters (DACs) for signal conversion, various communication interfaces like CAN, LIN, and Ethernet for Electronic Control Unit (ECU) interactions, and memory units like RAM, ROM, and flash for data storage. Additionally, VCUs have power supply units to provide stable power to onboard systems.
Central to the vehicle control unit is its software, which is fundamental in enabling the VCU to effectively manage and synchronize the electric vehicle's complex systems. The software within the VCU plays a pivotal role in enhancing the vehicle's overall performance, safety, and energy efficiency by executing advanced control algorithms and supporting diagnostic and safety functions. This makes the software not just a part of the VCU, but the core element that enables the VCU to function as the vehicle's intelligent control center.
As we delve into the world of VCUs, it's essential to understand that their role extends far beyond that of traditional Engine Control Units (ECUs) found in combustion engine vehicles. ECUs primarily focus on managing engine performance and emissions. In contrast, EV powertrains host more electrical components, therefore VCUs engage in a more complex set of tasks – from regulating battery usage and energy regeneration to ensuring the smooth operation of electric drivetrains and supporting ADAS.
The significance of VCUs in the development and performance of EVs cannot be overstated. They are the linchpins in making electric vehicles more efficient, safe, and user-friendly. By coordinating between various subsystems, VCUs ensure that electric vehicles can meet the high expectations of modern consumers regarding performance, reliability, and sustainability.
Moreover, as vehicles become more connected and integrated with digital networks, VCUs also play a critical role in enabling features such as over-the-air updates, real-time diagnostics, and enhanced cybersecurity measures. These capabilities are essential in maintaining the longevity, safety, and relevance of electric vehicles in an ever-evolving landscape of e-mobility.
The VCU performs several crucial functions that are key to the operation, performance, and safety of the EV. Here are the core functions of the VCU:
In addition to these core functions, VCUs are being developed to support increased functionality integration, aiming to centralize as many vehicle functions as possible into a single unit. This trend enhances vehicle efficiency and reduces complexity by decreasing the number of separate ECUs needed.
In EVs, a vehicle bus or bus network refers to the data transmission system that enables various electronic components such as the Vehicle Control Unit or traction inverter to exchange information and coordinate operations using protocols. A DC bus is the electrical pathway that carries high-voltage direct current from the vehicle's battery to components like the electric motor and traction inverter. While the DC bus distributes power necessary for the vehicle's propulsion and electrical functions, a data bus facilitates digital communication for system management and efficiency.
A vehicle bus allows the VCU to send and receive data and information across various components of the EV powertrain in real time, the most common being the Controller Area Network (CAN) bus, supporting bit rates between 40 kbit/s and 125 kbit/s. Besides CAN, other common bus protocols such as LIN (Local Interconnect Network), FlexRay, Ethernet, and Media Oriented Systems Transport (MOST) might also be used depending on the vehicle's requirements. Here's how they work:
The CAN bus allows microcontrollers and devices to communicate with each other within the vehicle without a host computer. It is known for its robustness and error-handling capabilities, making it suitable for critical applications like controlling the electric motor or battery system. Through CAN messages, the VCU can send commands to the traction inverter to adjust the speed and torque of the motor, request battery status updates, and receive data from various sensors. It is important to note that while the VCU doesn't directly control the torque and power delivered to the motor, it calculates and commands what is needed based on driver input and vehicle status. The traction inverter then translates these commands into action, adjusting the motor's operation accordingly. Additionally, CAN supports various higher-level protocols like DoCAN, UDS, OBD-II, and J1939, extending its application range within automotive systems.
The LIN protocol is a low-cost, low-speed alternative protocol, typically used for non-critical communication or to connect less complex devices in the vehicle, such as climate control or window and seat operation. While not primarily used for core powertrain components, it supports the overall vehicle network that the VCU may also interact with. It adheres to the ISO 17897 standard and features a single-master topology, meaning only one master control unit can initiate communication, but multiple slave devices can respond. This system operates using a single-wire interface, simplifying wiring, and reducing costs. LIN's design allows it to integrate easily with existing automotive technologies. It can be driven by the standard UART (Universal Asynchronous Receiver-Transmitter) interface found in many microcontrollers, which means changes required to support LIN on silicon hardware are minimal.
This is used for data-intensive applications that require higher data rates and deterministic behavior, such as advanced driver-assistance systems (ADAS). While not as common as CAN for powertrain components, it supports the VCU in high-performance applications, supporting communication speeds up to 10 Mbit/s, significantly faster than traditional automotive network standards like CAN or LIN. FlexRay's design includes advanced features such as dual-channel configurations for enhanced fault tolerance or increased bandwidth and the use of unshielded twisted pair cabling to connect nodes, minimizing the effects of external noise without the need for expensive shielding.
Increasingly being used in vehicles for its high data transmission speed and high immunity to electromagnetic interference, Ethernet supports advanced applications such as autonomous driving and comprehensive diagnostics. While not the primary communication method for traditional powertrain components, it is becoming more relevant as vehicles become more connected and data-intensive. Automotive Ethernet adapts the traditional Ethernet framework to meet these needs, modifying its physical layer to function over a single unshielded twisted pair of wires, known as 100 BASE-T1, aligning with the IEEE 802.3bw standard. It supports higher data rate variants and is compatible with standard networking protocols (TCP, UDP, IP) and automotive-specific protocols (DoIP, UDS, SOME/IP). Additionally, it accommodates high-performance layer-2 protocols such as AVB/TSN and TTE.
MOST technology is particularly adept at transporting high-quality service for audio and video streams alongside packet data and real-time control. Designed to meet the needs of advanced automotive multimedia systems, MOST supports synchronous and isochronous streaming with minimal communication overhead, leveraging a function-oriented approach and standardized APIs for seamless device networking. It employs a synchronous time-division-multiplexing network that ensures reliable data transport across various channels without interference. Adhering to the ISO 21806 series and structured according to the OSI basic reference model, MOST integrates seamlessly into automotive environments, promoting efficient and flexible multimedia device communication while providing scalable solutions through automotive-ready Ethernet compatibility. This makes MOST integral to modern in-vehicle infotainment and control systems, offering a structured, high-performance network for multimedia applications.
Regarding the programming languages used within the VCU firmware, it largely depends on the complexity of the control unit, the manufacturer, and specific requirements. The traditional programming languages used in the automotive software domain, especially for embedded systems like VCUs, are C and C++. These languages are favored due to their suitability for resource-constrained embedded systems and their performance efficiency. C is often used for its proximity to hardware, enabling direct manipulation of machine-level operations, while C++ provides object-oriented features, facilitating modular and scalable code architecture.
While there is growing interest in the programming language Rust due to its emphasis on safety features, such as memory and thread safety, which are crucial in automotive applications, it is important to note that Rust is part of a broader landscape of programming languages being considered for such applications. The transition to or incorporation of new languages like Rust into automotive software development is influenced by several factors, including existing code bases, project requirements, and industry standards. It's not a straightforward replacement but an addition to the toolset that may offer benefits in specific contexts.
Simulink, part of MATLAB’s suite, is widely used for model-based design in automotive applications like the VCU, allowing for the development of control logic, automatic code generation, and simulation integration with automotive standards like AUTOSAR. It allows engineers to design, simulate, and test control algorithms in a graphical environment before deployment.
Overall, the choice of programming language and communication protocols depends on the specific requirements of the vehicle's powertrain system, including performance, safety, and real-time constraints. For many embedded systems, C or C++ will be the best choices because of their efficiency and control over system resources, essential in environments where timing and performance are critical.
Exro's SEA-Drive® VCU represents a leap forward in the field of vehicle control technology, embodying the essence of innovation and adaptability in electric vehicle management. Distinct from conventional vehicle control units, the patented SEA-Drive® VCU, leverages a proprietary software architecture reminiscent of an octopus, where each 'tentacle' can independently manage different vehicle functions while maintaining cohesive system-wide harmony. This architecture provides an unparalleled level of flexibility, allowing for the rapid integration of new components and technologies as well as facilitating seamless updates and upgrades without the need for comprehensive overhauls.
This 'octopus' software design is central to our approach, emphasizing the importance of adaptability in an ever-evolving technological landscape. It enables our VCU to accommodate a wide range of components, from traction inverters and motors to auxiliary systems like air conditioning and power steering, thereby expediting the electrification process for OEMs. This adaptability is critical, as it significantly reduces the time to market for new or updated electric vehicles by streamlining the integration of power electronics and software, areas where many OEMs face challenges during the electrification transition.
Moreover, the SEA-Drive® VCU is distinguished by its comprehensive control capabilities, overseeing more than 20 critical functions within the electric vehicle ecosystem. This centralized control, coupled with an intuitive driver interface that delivers essential operational data directly to the dashboard, enhances both the driving experience and vehicle efficiency. The VCU's design is backed by over 3 million miles of real-world data, providing tangible proof of its reliability and effectiveness in managing electric vehicles.
What truly sets the SEA-Drive® VCU apart is its holistic approach to vehicle efficiency and management. This system-level perspective allows the VCU to optimize the entire vehicle's performance by ensuring that all components work in concert towards maximizing efficiency. For instance, by facilitating direct communication between the VCU and the Battery Management System (BMS), it precisely controls the C-rate discharge to maintain optimal battery temperatures. This strategic management negates the need for traditional liquid cooling systems, leading to significant improvements in operational efficiency. The elimination of liquid cooling not only simplifies the vehicle's cooling infrastructure but also allows for the use of a smaller radiator, further reducing energy consumption and enhancing the vehicle's range.
Another example of the SEA-Drive® VCU's efficiency-enhancing capabilities is its intelligent control of the vehicle's radiator. Unlike traditional systems where the radiator operates continuously whenever the vehicle is on, the SEA-Drive® VCU employs temperature sensors to modulate the radiator's activity, activating it only when necessary. This targeted approach prevents unnecessary power drain, contributing to an overall increase in system-level efficiency and vehicle performance.
By centralizing control and integrating data across the vehicle, the SEA-Drive® VCU not only streamlines the management of power electronics and software but also significantly accelerates the electrification process for OEMs. This reduces time to market for new electric vehicles and addresses common electrification challenges. With more than 3 million miles of real-world data backing its reliability, the SEA-Drive® VCU is not just the brain behind the vehicle's operations but also a key enabler of future-proof, efficient, and high-performing electric commercial vehicles. This advanced level of control and efficiency underscores Exro's commitment to leading the electric transition in the automotive industry, providing solutions that go beyond conventional expectations to meet the evolving needs of both OEMs and end-users.
