The adoption of electric vehicles is steadily progressing, and every link in the supply chain is undergoing changes. This encompasses raw materials, chemicals, batteries, and various components used to manufacture electric vehicle parts. Simultaneously, vehicle charging infrastructure is also involved, undergoing a historic phase of complete redesign. Their electrification, along with government regulations, presents challenges to the design and development of new automotive networks and software. Electronic system architecture, the structured configuration of all electronic components, modules, and networks within a vehicle, defines its electrical and electronic composition. Specifically, electronic hardware, network communication systems, software, and all circuit wiring are integrated to enhance control over various aspects of the vehicle's functions.
Electric vehicles are more than just vehicles with electric motors; they are equipped with highly complex peripherals and sophisticated electronics, enabling a wide range of applications. An electric vehicle is a complex technological system whose operation is based on physical, chemical, electrical, and electronic fundamentals. It is equipped with an independent power source battery and various circuits dedicated to performing different functions. A good architecture must consider the power and information requirements of all electrical devices in the vehicle. While the purely mechanical aspects are roughly similar to those of a traditional internal combustion engine vehicle—such as the wheels or chassis—the electrical components are quite different, encompassing numerous new design differences. These involve the battery system for traction, the electric motor, power regulation circuitry, and circuitry dedicated to battery charging. The basic configuration of an electric vehicle consists of one or more batteries, an energy converter, an electric motor, transmission components, and a differential system that controls the wheels.
There are more efficient systems without a differential, propelled by two motors, one for each drive wheel. In this case, two independent conversion systems are required, even though only one battery power source is available. With technological advancements in recent years, new architectures have improved system efficiency and connectivity, and have also integrated communication protocols such as CAN, LIN, FlexRay, and Ethernet. Today, with the increasing use of electronics in vehicles, a well-designed architecture is essential for improving reliability and safety while driving, as well as increasing efficiency by reducing energy consumption, weight, and cost (see Figure 2). Thanks to improved connectivity strategies and the use of fast local gateways, new electric vehicles are configurable and intelligent. Currently, thanks to new, highly complex integrated circuits and electronic solutions that can only be achieved with new electronic components, new applications that were previously unimaginable can be set up.
Electric vehicles are not all the same; they follow different design types. However, a key characteristic lies in the percentage of electrical energy used for propulsion. Some cars use only electricity for propulsion, while others combine electricity with other forms of energy, a process defined as "hybrid." Broadly speaking, the former utilizes propulsive energy entirely provided by power sources such as batteries or fuel cells. The latter uses various propulsive energy sources, at least one of which is electricity. Electric vehicles are designed primarily to achieve their autonomy, maximizing speed and acceleration. As shown in the diagram above, the electric traction system consists of various functional blocks: an electric motor works in conjunction with a power converter, connected by wiring. The circuitry connects to an energy storage system and is supplemented by an external charging system. Traction is controlled by multiple devices. Of course, an auxiliary liquid cooling system is also needed to maintain the system at safe thermal levels.
Battery and BMS
One of the fundamental components of an electric vehicle is the battery, which, along with performance-optimized circuitry, forms the vehicle's propellant. The battery stores electrical energy, powering the engine and all other parts of the car. Currently, lithium-ion batteries are the mainstream technology, achieving a good balance between energy density, durability, and weight. Under this power, complex safety systems must be implemented to provide protection against extreme thermal conditions, replenish electrolytes to prevent unavoidable fuse failures, provide ventilation to prevent gas leaks, and balance the charge, as the various components of the battery often have different potentials during charging and discharging, leading to imbalance problems. These components are managed by a control and monitoring system; the BMS (Battery Management System) regulates charging and discharging commands, as well as thermal and power controls, to ensure maximum efficiency.
The Battery Management System (BMS) can be considered the brain of an electric vehicle. It continuously monitors all electronic systems, batteries, engines, power supplies, and auxiliary equipment to ensure the vehicle operates safely and optimally. PYLONTECH's 48V 2.4 kWh lithium-ion battery and inverter require a BMS to function properly. The wiring between electronic components must also be carefully designed. The enormous power levels involved mean meticulous planning is necessary, especially in the cabling section, which will undoubtedly impact the system's weight and size. Long-term sales forecasts for new electric vehicles are optimistic, projected to grow by several tens of percentage points over the next few years, as the entire industry commits to significantly reducing carbon emissions across all activities.
electric motor
An electric motor converts electrical energy into mechanical energy to propel the wheels. There are various types of electric motors, such as asynchronous induction motors and permanent magnet motors, each with its own advantages and disadvantages. The choice of motor depends on various factors, such as performance, efficiency, and cost. In electric vehicles, the electric motor is typically located near the wheels and is powered by a set of rechargeable batteries. When the accelerator pedal is pressed, the electric motor draws energy from the battery pack and transmits motion to the wheels. It is characterized by instantaneous and constant drive torque, enabling very smooth and quiet acceleration. Typically, an electric motor consists of a rotor (rotating part) and a stator (stationary part).
At the heart of the electric motor is power electronics, which plays a crucial role in energy management. It converts battery voltage to a level suitable for the motor via DC-DC and DC-AC devices. Recent research aims to recover energy from physical events, such as braking energy. During braking, kinetic energy is converted into electrical energy and then stored in the battery. This process slightly increases the vehicle's driving range. All components of an electric vehicle do not operate in isolation but constantly communicate and exchange data and information through a communication network. This new concept allows for the real-time exchange of system status data, activating intelligent control strategies for all vehicle components and coordinating the collective operation of different components.
in conclusion
The first thing that draws attention to electric vehicles is their quiet operation, which helps reduce both air and noise pollution. The structure of an electric vehicle's electronic system is, of course, a highly complex field, with numerous components at work. Its primary focus is on minimizing environmental impact, taking into account the entire supply chain, from raw material production to user battery charging. Electric vehicle electronic systems are constantly evolving, with related innovations extending to autonomous driving and driver assistance, leveraging artificial intelligence to enhance safety and comfort. A flawless and superior architectural design is crucial for the development and future of this revolutionary technology.
