May 21, 2024

Automotive electronic hardware design method

On the EE album, I saw an article by blogger Rocky about the hardware design of the communications industry. I lament that the issues considered between different industries are similar, but the environmental conditions are different, the functions are different, and the reliability requirements are different. Even the hardware design between different products inside the car electronics is slightly biased in the direction. There are many branches of automotive electronics. The chassis and engine control direction is biased towards system control. The energy conversion unit is biased toward the optimization of switching power supply and there are more coincidence intervals between entertainment electronics and consumer electronics. The exchange of work with colleagues in the old days probably also confirms the different developments of different branches.

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Power consumption

Now understand that the capacity of 12V lead-acid batteries is about 50~100Ah. The power consumption mentioned here refers not only to the power consumption during operation, but also to standby power consumption. The former is seen in the entertainment system. If you don’t have a car to play, you will be funny. I did an experiment a few days ago. I can't start the car with the 15V150A power supply. The instantaneous power required at startup is very high, and it also puts high requirements on the battery capacity. The power consumption of sleep will directly determine the number of days the car is stored. Although there are more and more electronic devices, it is unacceptable to be unable to launch in less than one month. Especially in the future PHEV and EV, the main relay can't be sucked up when the voltage is low.

2. Reliability

Compared with communication equipment (believe or subdivided into home use, field use), harsh conditions and safety-related attributes, as well as people's increasingly high warranty requirements (long-term warranty for Korean car companies in the US) The policy is really stressful, and the development model of all modules may be subject to certain changes. The combination of MTBF and functional fault DFMEA makes the entire design more comprehensive.

3. Thermal design and thermal analysis

VOLT is equipped with three sets of cooling systems. It is believed that the increasing use of power conversion units will increase the difficulty of thermal analysis and thermal design for the entire module. Of course, when the heat accumulates to a certain extent, it has to be considered to be discharged from the entire vehicle. The device-level heat dissipation design is relatively simple (according to previous calculations and simulation results, IGBTs and MOSFETs are worth noting in general high-power applications, others As long as you choose the right LDO, the general problem is not big.)

4. Device procurement and cost control

Interestingly, local companies often use the best chips. This is what I told my colleagues from BYQ before, and they all use good things to make mistakes. At least the chip level can provide support and guarantee. Innately, the cost of some tests is reduced. In fact, the premise of cost reduction is to obtain the stress and margin of each device in order to optimize the technology cost. No King Kong turns, don't take porcelain.

5.DFM and DFT

If you can't produce or leave some non-conforming products, the price will be shocking. Therefore, the cost of EOL equipment is often high and scary. Some places are subject to cost considerations and must be used before calibration before going offline.

6.EMC and EMI

I used to think that the EMC and EMI of the electronic module were very challenging. Now I find that the source may be as many wires as the car. Due to the many inductive loads and distribution characteristics, the last power supplier asked me if there is ripple in the 12V battery itself. It makes me feel very surprised. When I get to the car, it is not surprising to see where the conduction or space is coupled to a certain amount of noise. This is especially true for future electrified cars. In fact, EMC at the vehicle level is in trouble. If you don't see it, you will pack it out and test it.

7. Regulations and standards

I have found out that there are so many standards, regional, industrial, international, and national; mainly based on test standards, as well as safety standards, etc., there have been some introductions. Fortunately, the country is always the easiest to pass, if everyone wants to pursue it.

8. Power supply design

This piece is indeed a big problem. In the face of more and more integrated systems, the traditional LDO seems to have changed a bit. The same point of view as Rocky is that when encountering analog signal acquisition, the error and interference of the power supply itself need to be taken into consideration. If some analog sensor harnesses are too long, some considerations may need to be made to the ground.

9. Noise and vibration

Relays, large inductors and other magnetic components are all possible to sound. Moreover, the latter two are relatively sensitive to vibration. In the future, the electrification process will use a large number of flat-panel transformers and large inductors. I believe this is the hardest hit area of ​​the design.

I have made some narratives on the original 11 points. I feel that I have said it once or twice before, and I have already written it once or twice. I hope that I will pay attention to and interpret the hardware design method from the perspective of a product/system engineer. I wish Yan Xiong to be happy on this road. The colleagues in the previous hardware group have all gone well.

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