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The Impact of Vehicle Electrification on Electrical System Design Automotive Siemens PLM Software The impact of vehicle electrification on electrical system design Automotive Dan Scott Integrated Electrical Systems, Mentor product suite siemens.com/mentor White paper | Impact of vehicle electrification on electrical system design The impact of vehicle electrification Introduction Growth in electrical content Electrical distribution systems (EDS) are designed within Conventional wisdom has it that over the last decade or a broader multi-domain context. Given the accelerating two, the global auto industry has undergone waves of trends of vehicle electrification and autonomy, carmak- disruption, each larger than the last. First was the rise ers and suppliers are evaluating their EDS processes and of China as a major vehicle market (now the world’s tools with renewed scrutiny. And it’s not just estab- largest in terms of both demand and supply), second lished industry players demanding more from EDS ven- was the introduction of mainstream hybrid-electric dors. At a recent count there are approximately 300 vehicles, last was the rise of autonomy and mobility companies developing electric cars and light trucks, services. with nearly 100 companies having announced autono- The images below show why it’s autonomy that ulti- mous drive programs. Many of these companies are mately looms largest in terms of EDS impact. First, on new entrants to the automotive industry and are work- the left, is a picture of the low-voltage harness of the ing to disrupt the status quo. Chevy Bolt EV, introduced to much acclaim in 2016, Autonomy and electrification are demanding significant in-part because of its nearly-400 km-to-a-charge range. changes to electrical and electronic architectures within Now consider the second image, at right, which is the vehicles. This is due in part to the introduction of high autonomous version of the Bolt, not currently a produc- voltages, increased safety considerations and significant tion vehicle. At a glance, autonomy’s impact on EDS is weight reductions needed to maximise vehicle range obvious. In fact as part of a GM investor presentation in from electrification, and ‘fail operational’ designs, November 2017, the company described the addition of hugely increased data network loading and virtual 40 new sensors and a 40% increase in new hardware validation requirements from autonomy. The race to content compared to the non-autonomous version 1. electrified self-driving cars is on. In this article I’ll look at some of the implications of autonomy and electrification, and then have a deeper dive into the technical implications of high voltage electrification on how electrical systems are designed. Figure 1. Low-voltage harness for Chevy Bolt EV. Image courtesy Sam- Figure 2: Harness for autonomous Bolt. Image courtesy Sam Abuelsamid, Abuelsamid, http://sam.abuelsamid.com. http://sam.abuelsamid.com. Siemens PLM Software 2 White paper | Impact of vehicle electrification on electrical system design Figure 3: Evidence for electric vehicle momentum, including free charging stations, is apparent in cities around the world. Still, autonomy, especially full Level 4/5 mostly hands- lot of this rush to market and consequent pressure on off driving, remains a number of years away. Despite product development times is now driven by fear of ample marketing noise and news coverage, most expect being left behind rather than by trying to be a first autonomy to enter a well-known “trough of disillusion- mover. As a result of this activity, design organizations ment” as described by Gartner. Indeed of late, self-driv- need processes and tools that allow them to respond ing stories have seemed to focus on more modest appli- rapidly to change. Old interactive processes are inad- cations like shuttles operating at relatively low speeds equate to move as quickly as is now needed, which is in geo-fenced areas. leading organizations to invest in high levels of design automation and virtual validation. This is not the case when it comes to electrification, which if anything is accelerating, thus impacting prod- So what will the some of the specific implications of uct development times as well, including the work of high-voltage electrification be on EDS designers and EDS design teams. Companies large and small, and all what characteristics will they need from their design levels of government, from the national- to the village- tools? level, continue to declare their electrification plans. A Siemens PLM Software 3 White paper | Impact of vehicle electrification on electrical system design Figure 4: Mounting harness complexity spurs the need for design tools, like Mentor’s Capital suite, for managing a long list of design rules and checks. Capital automatically generates circuits to optimize length and routing, and to check for circuit completeness. Multi-domain design and safety A necessary and indeed primary aspect of the electrical Electric vehicles require a greater focus on true multi- system design for high voltages is to ensure there are domain system level design. A simple example is regen- safety mechanisms to prevent electrocution (driven by erative braking. The addition of high power electric good professional engineering practice and also to motors, power electronics and high-capacity battery satisfy section 5 of UN ECE Reg 100). A High Voltage storage means that braking systems now have to con- Interlock Loop (HVIL) is introduced to the design of high sider the dynamics of high-power electronics, motor voltage electric vehicles to provide electrical safety characteristics, battery electrical safety as well as cell when, for example, high-voltage connectors are chemistry to understand and manage the capturing of removed as part of vehicle fault finding or correction. It braking energy. It is no longer only rejected as heat via is preferable to verify the HVIL protection at the design the friction brakes, but can also be converted into use- stage. It is necessary to confirm that no high-voltage ful energy again via storage in the battery. The design connectors and components have been accidently omit- of this system requires a new level of close integration ted from the HVIL circuit design. In addition, we need to between mechanical, electrical and thermal domains. It confirm that the circuit offers the required protection becomes necessary to have true multi-domain data when continuity is broken and that circuit sensing hap- exchange between engineering software tools to inform pens at the correct points within that circuit to locate the system design from an early concept stage. At the faults expediently. This is a key part of the overall vehi- most progressive automotive OEMs, thermal, electrical cle electrical safety and fault detection strategy. Using and mechanical designers work increasingly closely Mentor’s Capital tools, it’s possible for a company to together when designing HV electric powertrains, as generate a set of design rules and checks that support each of their ‘independent’ decisions significantly the auto-generation of the HVIL circuit to optimise impacts the others. (See the Mentor whitepaper length, routing and so on, and also to check for circuit “Automotive ECAD-MCAD Co-Design Leads to First-Pass completeness. Success.”) Siemens PLM Software 4 White paper | Impact of vehicle electrification on electrical system design Figure 5: Mentor, a Siemens business’ Capital UI for defining electrical systems and network domains. Other consideration: Heat, weight and vehicle start- Optimizing packaging and weight requires deep integra- up / shutdown tion between electrical and mechanical design tools. Localized heating of connectors is an issue which would This is a key concern for electric vehicles. For example a be better supported with tools that are integrated like-for-like comparison between a 2017 VW Golf SE between mechanical, thermal and electrical domains. A gasoline vs e-Golf shows a 32% unladen weight increase related design consideration is ultra-high power DC in the electrified version. And the picture gets even charging systems (150-350kW+), which require careful more stark when autonomous packages are added to thermal analysis of the vehicle-side charger mating the mix. A recent paper by researchers at the University connector, and HV cabling to the battery. It’s also ben- of Michigan and Ford suggested that large autonomous eficial to be able to analyse the total thermal losses in systems might actually increase net energy consump- the HV system to contribute to range estimations and to tion of self-driving electric vehicles, despite the vehicles’ ensure suitable thermal clearances for HV cables are ability to optimise the driving profile 2. maintained. With the electrical distribution system as the third Ensuring the as-designed HV electrical system is isolated heaviest system in a vehicle (after the chassis and pow- at the design stage saves later re-design and potential ertrain), reducing EDS mass makes a vital contribution physical rework. Embedding design rule checks in elec- to overall vehicle weight targets. Managing the physical trical system design software enables this checking to size and mass needed to conduct high currents is one of be automated leading to a much higher level of confi- dence in the design at an early stage. Siemens PLM Software 5 White paper | Impact of vehicle electrification on electrical system design the more significant challenges in designing EV connec- incorporated into a representative topological layout of tors and cables. One example that OEMs are consider- that vehicle. Systems devices are automatically placed ing is in removing and/or reducing HV cable shielding to and interconnected, and the entire wiring system is optimize weight and packaging. An obvious implication automatically generated using rules and constraints of this is the need to manage electro-magnetic interfer- embedded by the company into the software. The result ence via integrations with tools to analyse high and low is design tasks that took months can now be achieved in frequency emissions from sources such as HV cables, hours or days and, critically, the designs can be verified the battery management system and power electronics.
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