Automotive industry 4.0: new revolution?

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The concept of the automotive industry is often misunderstood, simply linked to cars and related applications. In fact, it is much wider than this, covering a much wider range, such as buses, trucks, industrial vehicles, mobile machinery such as mini equipment, forklifts, automatic cleaning vehicles, emergency and service vehicles. Everyone is talking about the increasingly famous Industry 4.0, often involving the fourth-generation industrial revolution.

Industry 4.0 provides the so-called "smart factory." In a modular, intelligent factory, the information physics system monitors processes, creates virtual copies of the physical world, and decentralizes decisions. In the Internet of Things, information physics systems can communicate and cooperate with each other in real time, and also communicate with humans. Through the Internet services, internal and all organizational services are provided and used by participants. Affected by Industry 4.0, the automotive industry has the concept of Automotive 4.0.

In 2016, more than 60% of cars were equipped with color screens as part of the infotainment system. The quality of information provided to drivers and passengers is very high. We all expect the same user experience from our car, just as we get information from our other personal devices, entertainment and high-speed connectivity. These increased expectations have complicateed the automaker's interoperability and security, especially when considering future 5G and smart vehicles.

Although the screen is a visible corner of the "iceberg", other unseen large numbers of calculations, sensors, and other components make the car safer and more reliable. But in general, they need increasingly efficient and powerful power solutions. Power management in the automotive industry is typically implemented by a set of power management integrated circuits (PMICs), which are partially centralized embedded computer systems. Semiconductor manufacturers offer a wide range of PMICs, with next-generation digital control and advanced communication interfaces.

If the automotive industry represents the mass market of automotive infotainment systems, as the growing demand for communication between large cities and cities grows, existing train networks are often insufficient to meet the needs of passengers, and other public facilities are needed to be more effective. Meet the needs of passengers.

A recent study reported that the global demand for buses in 2018 is expected to exceed the annual growth rate of 64,000 to 664,000, which is twice the growth rate in 2008-2013. The number of buses used worldwide is expected to exceed 8 million units that year, and many of the advanced infotainment and vehicle monitoring equipment require stable and reliable power solutions.

Connecting bus

With the development of aircraft and a new generation of high-speed trains, entertainment equipment is usually installed in passenger seats, which requires local power sources to be free of line interference, low-level radio emissions and the ability to work without forced air cooling. In addition, bus manufacturers require seat manufacturers to make seats simpler, easier to maintain (and upgrade), and less wiring and interconnection.

The seats that meet these requirements will depend on a simplified connection, limited to one power cord and one fiber for data transmission, meaning that the power supply to the entertainment device must be installed in the seat, which requires a lot of power.

For decades, the power supply for this device was placed under the seat, convective cooling with free air. But the new generation of power modules must work without airflow, so they must optimize the design to use conduction cooling (such as the substrate attached to the seat armature). In order to reduce power loss and optimize cooling, power converters require a very high efficiency dissipative component to be directly connected to the substrate (Figure 1). This technology is applied to high power density converters In the telecommunications industry, such as planar transformers, heat pipes, hot drain pipes, in some cases, heat pumps are also used in the automotive industry.

Figure 1: Powerbox's ENAR100/200 is a new generation of DC/DC DC converters His design meets the "one-size-fits-all" approach, integrating advanced thermal management and efficient topologies for use in the automotive industry.

Power converters for power supply equipment used in automobiles In compliance with international standards, such as ISO 7637, road vehicles that specify electrical interference conduction and coupling test conditions use 12V or 24V batteries (Figure 2), requiring power companies to work closely with equipment manufacturers to ensure that the final product can be in a compliant environment. Working in the middle.

Figure 2: This example iso7367-2 pulse test motivates the starter circuit of an internal combustion engine to simulate a reduced supply voltage. ISO7367 covers a wide range of electrical interference tests

Fleet management

Few people realize that modern buses are equipped with impressive advanced electronics and therefore require a stable and sustainable power supply (Figure 3). Reliability and optimization of fleet management, a new generation of buses are equipped with real-time tracking to connect to the navigation system, including engine conditioning and safety equipment such as driving behavior analyzers. The monitoring system permanently reports on the status of the vehicle, possibly managing preventive maintenance and reporting the location of the fleet to the central coordinator.

Figure 3: The application is installed on a modern bus and requires a stable power supply and safe operation of some car batteries.

For the sake of safety, to ensure the continuity of important functions, after the main battery is powered off, a backup strategy is required, including the battery of the car requires a micro charger. These miniature chargers share similar infotainment system power supplies because they are typically installed in a confined environment. Therefore, they need to have a highly efficient design to optimize the thermal management of the conduction cooling mechanical structure. Designing to reduce potential failures due to thermal stress is critical and ensures high reliability of the product on the road.

Designers must also consider the specific requirements of battery charging optimization, such as measuring battery temperature and, in some cases, communication between the battery charger and the central monitoring system. This requires consideration of the appropriate comparisons and performance of previous generations in the overall design process, primarily based on analog control, the latest generation of integrated microcontrollers and real-time charging optimization. Some would say that adding digital control to a micro-charger is an overkill technique, while others would argue that this technology has proven to be superior in terms of reliability and longer battery life.

But any controversy needs to take into account the need for power supplies to provide stable, reliable voltage infotainment systems and other electronic devices for use on buses. Bus manufacturers are increasingly asking power supply manufacturers to develop standardized DC/DC converters when upgrading their equipment . , charger, buck regulator, easy to install, maintain and higher power requirements. The concept of “one-on-one” is no longer a dream, but it has become a reality and has added mechanical challenges, as well as some corresponding design parameters.

Power supply designers have spurred the modernization of buses and buses, and the new generation of modern information and advanced electronic devices are impressive, providing the opportunity to bring advanced power technology, which has been slow to adopt new technologies for some time, and now it is big Step to the car 4.0. Perhaps this is the fourth car revolution that early adopters call it!