The modern automobile has evolved from a mechanically dominated platform into a highly complex "integrated software and hardware system." This blog will start from the macro framework and dissect the core components of automotive electronics layer by layer: it first explains the "digital foundation" built jointly by the hardware platform and software architecture, then delves into the functions and interactions of five key electronic systems. Finally, the article will focus on a core transformation—how the rise of new energy vehicles has significantly elevated the performance requirements for Printed Circuit Boards, revealing how this technology, hidden behind the vehicle, has become a key force driving the evolution of the automotive industry.
In this article:
Part 1. Software and Hardware Framework Part 2. Five Major Parts Part 3. PCB Requirements: New Energy Vehicles vs. Traditional Gasoline VehiclesSoftware and Hardware Framework
Within the vast domain of automotive electronics, its technological framework can be understood as several interconnected core layers. Together, these layers form the “nervous system” and “decision-making system” of modern vehicles.
From a macro perspective, the automotive electronics framework can first be divided into two main pillars: the hardware platform and the software architecture. The hardware platform serves as the physical foundation of the electronic system, akin to the skeleton and sensory organs of the human body. It bears all functions and perceives the external environment. At this level, the most critical component is the Electronic Control Unit (ECU). These microcomputers, distributed throughout the vehicle, specialize in controlling specific functions such as engine management, anti-lock braking, or window operation. Connected via vehicle networks—particularly Controller Area Network (CAN bus), LIN bus, and the increasingly prevalent Ethernet—these ECUs form a highly efficient, collaborative system. Additionally, diverse sensors and actuators form the interface between the hardware platform and the physical world. Sensors act like nerve endings, continuously gathering signals such as temperature, pressure, and position; actuators function like muscles, executing specific mechanical actions based on commands.
Above the hardware lies the software architecture responsible for coordination and management. As automotive functions grow increasingly complex, traditional distributed architectures are evolving toward standardized frameworks like AUTOSAR. AUTOSAR provides a universal software architecture blueprint that separates base software, runtime environments, and application layers. This allows software from different suppliers to be flexibly combined like building blocks, significantly enhancing development efficiency, portability, and scalability. This lays the foundation for continuous vehicle functionality upgrades.
Deep integration of hardware and software forms the functional domain framework for implementing specific capabilities. This represents the cutting edge of automotive electronics development. To replace the chaotic landscape of hundreds of ECUs operating independently, automakers are increasingly dividing vehicles into core domains based on function. For example: the Body & Comfort domain managing seats, climate control, and lighting; the Chassis & Safety domain controlling brakes, steering, and airbags; the Infotainment domain focusing on the center console screen, navigation, and audio systems; and the most complex domain, Autonomous Driving, which aggregates data from radars and cameras for real-time computation and driving decisions. This domain-based control architecture simplifies system complexity while reducing wiring harness weight and cost.
Five Major Parts
Powertrain
The engine control unit is the core, precisely calculating fuel injection quantity and ignition timing based on signals from various sensors to ensure efficient and smooth engine operation. Closely working in conjunction with it is the transmission control unit, which manages the shifting logic of automatic or dual-clutch transmissions, directly impacting driving smoothness and fuel economy.
Automotive Safety Electronic Systems
This includes both active and passive safety systems. Active safety systems aim to prevent accidents; for example, anti-lock braking systems (ABS) and electronic stability programs intervene during emergency braking or loss of vehicle control to help the driver maintain control. The airbag control unit, a passive safety feature, quickly assesses the situation upon impact and triggers airbag deployment to protect occupants.
Body and Comfort Electronic Systems
These components enhance ease of use and the riding experience. For example, the body control module acts as the vehicle's nerve center, managing functions such as windows, door locks, windshield wipers, and interior lighting. Advanced key and access control systems allow drivers to enter and start the vehicle without keys. Furthermore, the automatic climate control system maintains a constant interior temperature through electronic control.
Infotainment and In-Vehicle Networking
It connects the vehicle, the outside world, and the occupants. The infotainment system integrates audio, video, navigation, and smartphone connectivity, becoming the core of the modern car's intelligent cockpit. Meanwhile, in-vehicle networking technology is crucial to ensure efficient and reliable communication among all these complex electronic control units. Bus protocols such as Controller Area Networks (CAN) and Local Area Networks (LANs) constitute the vehicle's internal information superhighway.
Advanced Driver Assistance Systems and Chassis Electronics
Advanced driver assistance systems utilize radar, cameras, and ultrasonic sensors to perceive the surrounding environment, enabling driver assistance functions such as adaptive cruise control, lane keeping assist, and automatic emergency braking. On the chassis side, electric power steering provides precise and comfortable steering feel, while electronic suspension systems adjust damping in real time according to road conditions to improve handling or comfort.
PCB Requirements: New Energy Vehicles vs. Traditional Gasoline Vehicles
To be very precise, the requirements for PCBs in new energy vehicles are far higher than those in traditional gasoline vehicles in several core aspects.
This "higher requirement" does not refer to all PCBs, but rather to the fundamental shift in the technological paradigm of new energy vehicles, whose core systems pose unprecedented challenges to the performance, reliability, and complexity of PCBs.
I. Fundamental Changes in Powertrain Systems: From "Mechanical" to "Electrical" and "Power"
Traditional gasoline vehicles primarily use PCBs in engine control units, infotainment systems, and some body control components, handling relatively low voltages and currents.
However, the core of new energy vehicles is the "three-electric system"—battery, motor, and electronic control. This directly leads to:
II. The Leap in Complexity Brought by Battery Management Systems
The BMS is a unique and highly technologically advanced system in new energy vehicles, essentially the "brain" of the battery pack. It places extremely stringent requirements on PCBs:
III. The Superimposed Effect of Intelligence and Electrification
New energy vehicles are inherently the best carriers for "intelligent vehicles," meaning they must handle not only "power" but also massive amounts of "data."
In summary, the development trajectory of automotive electronics clearly points towards a convergent future of integration, softwareization, and electrification. From distributed ECUs to centralized domain control, from hardwired connections to software-defined features, the "nerves" and "brain" of the automobile are undergoing a profound revolution. In this transformation, the PCB, as the physical foundation carrying all electronic functions, has seen its role upgraded from a silent supporting actor to a core component determining vehicle performance, safety, and intelligence level. Particularly in new energy vehicles, the extreme demands placed on PCBs for power handling, heat dissipation, and data processing are the most direct testament to the metamorphosis of traditional transportation into "super mobile intelligent terminals." Ultimately, the synergistic evolution of software and hardware together weaves the intelligent blueprint for the future automobile, driving us towards a new era of safer, more efficient, and smarter mobility.
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- Micriavia filling with copper: laser via size 0.1-0.125mm, priority 0.1mm
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- Max aspect ratio for via-in-pad filling with resin PCB - 12: 1
- Min resin plugged PCB thickness: 0.2mm
- Max via-filling ith resin PCB thickness: 3.2mm
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- Via filling with copper/silver: Yes
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Conclusion
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PCB fabrication at PCBONLINE.pdf
