Zone control unit

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Overview

A zone control unit (ZCU) implements vehicle functions that are located within a certain physical "zone" of the vehicle. Within that zone, it aggregates various signal and communication protocols, controls a variety of local loads and manages the local power distribution. Zone controllers provide a means of structuring the increasing complexity of the electrical and electronic (E/E) system, enabling efficient and scalable vehicle architectures.

Benefits

Reduced SW & HW complexity
Improved scalability
High flexibility & configurability
Reduced weight and cost
Aggregation & updatability of SW
Better system performance

Block diagram

About

The evolution of E/E architectures: Shift towards zonal architectures

The automotive industry is undergoing a significant transformation in its electrical and electronic (E/E) architectures, shifting from traditional domain-based architectures to zonal architectures with central computing. This change is driven by the need for more efficient and scalable designs, as well as the rise of Software-Defined Vehicles (SDV) and wire harness optimization.

In a zonal architecture, the power distribution system is electrified, with zone controllers aggregating multiple ECU functions and possessing gateway, power distribution, and load actuation functionality. These controllers are linked to each other and a central car computer via an Ethernet backbone, enabling seamless integration and efficient operation.

To support this transformation, advanced chipsets are required that can be tailored to meet the specific needs of zonal architectures, ensuring reliable and efficient performance.

Software-Defined Vehicle (SDV) solutions

Ethernet solutions

Infineon's power distribution solutions - A platform-ready portfolio

Zone controller designs require scalable and flexible semiconductor chip-set solutions. Specific needs depend on the extent of functional aggregation, the diversity of gateway communication interfaces and protocols, the associated performance requirements, and the number of output variants for load control.

Infineon offers scalable product families to enable module designs fitting to all kinds of zonal controller variants. These include discrete and integrated power supply solutions, such as our OPTIREG™ product families, supplementary NOR Flash solutions and of course our microcontroller solutions: While the AURIX™ family enables ZCU-integration of high-end computing performance functions, the TRAVEO™ microcontrollers serve as a complementary low-end alternative for price-performance optimized zone controllers. Infineon's PROFET™ smart power switches, MOSFETS and corresponding gate drivers are best-in-class in terms of current scalability and adaptability. Our broad MOTIX™ solutions portfolio enables any power actuation functions that ZCU designers may encounter and finally our Brightlane™ Ethernet PHYs and switches enable data rate scalability up to multi-Gbit.

Easily adoptable ISO-26262 automotive PDC solutions

Infineon's AURIX™ microcontrollers are best-in-class for ASIL-D functional safety designs and are complemented by the TRAVEO™ family for ASIL-B needs (partly with ASIL-D island). Corresponding OPTIREG™ power supply solutions come with easily-implementable safety manuals, enabling not only a safe design, but also a quick realization of functional safety goals. The MOTIX™ motor control solutions and the PROFET™ smart power switches are ISO-ready and partly ISO-compliant with plenty of safety documentation available, allowing the overall easiest functional safety design in the market.

Meeting zone control unit connectivity needs with our advanced MCUs

Due to the aggregation of control functions in an ever-reducing number of control units and the simultaneous increase in sensor data, electronic functions and network capabilities, the connectivity requirements of zone control units are increasing immensely. This implies the need for improved computing power per zone controller MCU and also requires significantly more interfaces to end points. In some cases, multi-gigabit interfaces are required to accommodate communication along the in-vehicle network. Infineon microcontrollers and communication solutions address these challenges and set new standards in time-sensitive, multi-Gbit, safe and secure data processing. Infineon’s MCUs come in a wide range of connectivity options, from traditional automotive low-speed buses to very fast multi-Gbit Ethernet interfaces in lockstep with Infineon’s Ethernet solutions.

The optimal way to transport and use electrical energy in the car

Driven by an increasing demand for power in the car for ADAS, automated drive (AD) functions, central computing, electrical power steering, infotainment, electro-mechanical braking or brake-by-wire, automotive 12 V power distribution systems are reaching their limit. As a solution, the adoption of a 48 V-based system emerges as the most efficient and compliant approach for transporting and utilizing electrical energy within regulatory frameworks, particularly with regard to contact protection ISO 6469-3.

This has spurred significant discussions regarding a comprehensive car-level strategy, aiming to achieve substantial system-wide cost savings through significant enhancements in efficiency, power losses, and wire harness optimization – encompassing aspects such as component cost, weight, complexity, routing, manufacturing, and assembly – all achievable with a holistic 48 V approach.

With more and more applications potentially moving from 12 V to 48 V, requirements towards the automotive zone controller with its integrated secondary power distribution change significantly. Infineon supports this trend with forward-compatible system designs and a subsequent 48 V product portfolio.

How to get started with your zone controller design

When designing a zonal controller, customers face a variety of challenges. They need to balance the complexity of functional aggregation, the diversity of gateway communication interfaces and protocols, and the associated performance requirements, while also considering the number of output variants for load control. They have to optimize the overall system to ensure scalability, flexibility, and reliability, and design it to fit the specific needs of different vehicle or platform variants.

Infineon support customers in overcoming these challenges. Our core competences include operational excellence, a zero-defect mentality, global customer support, system competence teams, and adherence to the highest automotive qualification standards. We also offer a broad portfolio of products that meet the latest industry standards, such as AEC-Q 100/101 qualification, and provide extensive documentation and support for safety-critical applications. To get started with your zone controller design, please contact your Infineon contact to engage with our experts and leverage our resources, including self-support collaterals, whitepapers, application notes, evaluation kits, and datasheets.