Embedded Systems and Design & Development - Feb 16, 2026 | Afternoon | VisionAstraa EV Academy

Introduction to Embedded Controllers in Electric Vehicles

Overview of the Session

• The session focuses on embedded controllers specifically for electric vehicles, discussing their necessity and motivation.

• Topics include survey-based information, technical aspects, and implementation from sensors to actuators.

Technical Insights

• Introduction to commercial controllers used in electric vehicles, such as STDM32 and Texas Instruments C2000.

• Discussion on Electronic Design Automation (EDA) tools that aid in developing embedded controller projects.

The Role of Chips in Modern Vehicles

Chip Utilization in Cars

• A typical passenger car contains between 1,000 to 3,000 integrated circuits (ICs), performing various functions beyond traditional analog or mechanical systems.

• Transitioning from gasoline to electric vehicles significantly increases the number of electronic components required.

Functions of Embedded Controllers

• Embedded controllers manage a wide range of functions within electric vehicles, from engine control to operating sliding doors and windows.

• Each function is now assigned to specific chips, highlighting the importance of embedded controllers in modern automotive technology.

Opportunities for Innovation

Potential Areas for Development

• The presentation emphasizes areas where local solutions can be developed, particularly battery management systems which are often outsourced.

• Developing domestic solutions could reduce foreign exchange expenditure and contribute positively to the economy.

Market Insights on Electronic Chips

Financial Aspects

• A survey report indicates that the market for electronic chips was valued at $6.5 billion in 2024 with an expected growth rate of 10.2% CAGR (Compound Annual Growth Rate).

• This financial insight motivates participants to engage more deeply within this domain as even a small market share represents significant revenue potential.

Focus Areas for Future Development

• Battery management systems remain a critical focus area due to their central role as energy sources in electric vehicles while fuel cells are still experimental for most applications.

Battery Management Systems in Electric Vehicles

Overview of Battery Management Systems (BMS)

• Battery management systems are critical components in electric vehicles, performing a wide range of functions essential for battery operation.

• The discussion builds on previous sessions covering electrochemistry and the strategic placement of battery packs to avoid mechanical instability.

• Embedded controllers play a vital role in managing various functions such as voltage control, current monitoring, charge/discharge control, and energy management.

Functions of Battery Management Systems

• Key functions performed by BMS include protection mechanisms, cell balancing, power flow control, charging/discharging control, and temperature monitoring.

• Power flow is bidirectional in electric vehicles; thus, BMS must manage energy transfer from the source to the load and vice versa.

• All these functions are crucial for ensuring the safety and efficiency of battery operations within electric vehicles.

Role of Embedded Controllers

• Embedded controllers must constantly monitor input parameters to make decisions regarding necessary controls for effective battery management.

• These controllers handle everything from input processing to actuation based on real-time data analysis.

Challenges in Developing Embedded Controller Solutions

• Rapid technological changes pose significant challenges; solutions may have a lifespan of only four to five years due to evolving technologies like silicon carbide or gallium nitride devices.

• Engineers need to continuously upskill themselves to keep pace with advancements in technology within the EV domain.

Cybersecurity Concerns

• As electric vehicles move towards higher levels of Advanced Driver Assistance Systems (ADAS), cybersecurity becomes increasingly important due to potential vulnerabilities.

Types of Embedded Systems in Electric Vehicles

Powertrain Control System

• The powertrain control system is responsible for delivering power from the source to the motor based on user acceleration inputs.

Advanced Driver Assistance Systems (ADAS)

• Currently, most ADAS functionalities available are at level one; further advancements are expected as technology develops.

Embedded Systems in Electric Vehicles

Overview of Embedded Systems

• The critical role of embedded systems in battery management, including functions like over-voltage protection and controlling charging and discharging.

• Auxiliary functions such as infotainment and vehicle control units are also integral to the embedded systems landscape.

Types of Controllers Used

• Implementation typically involves microcontrollers or microprocessors, sometimes combined with digital signal controllers for enhanced functionality.

• Various electronic computing devices manage tasks from powertrain control to auxiliary functions within electric vehicles.

Key Applications in Electric Vehicles

• Major applications include steering systems, braking systems, energy recovery systems, thermal management, and vehicle-to-grid systems.

• Advanced Driver Assistance Systems (ADAS) are categorized into levels; most cars currently operate at level one or two, with high-end models reaching level three.

Attributes for Embedded Controllers

• Important attributes for developing embedded controllers will be discussed in upcoming sessions focusing on their application in electric vehicles.

Functions of Embedded Systems

• A wide range of functions must be considered when developing embedded systems for electric vehicles, starting from power delivery to auxiliary functionalities.

• Emphasis on understanding bus protocols used for information transfer across the vehicle's network.

Power Control Mechanisms

• Traction control is essential; it regulates torque applied to moving wheels based on user input (e.g., throttle pressure).

• The complexity of real-time calculations required by controllers includes speed monitoring and energy availability assessment.

Regenerative Braking Functionality

• Regeneration control allows capturing kinetic energy during braking that would otherwise be wasted as heat in traditional engines. This energy can be stored back into the source.

Electric Vehicle Control Systems Overview

Monitoring and Decision-Making in Electric Vehicles

• The vehicle's embedded controllers continuously monitor parameters to decide the direction of power flow, either from the source to the motor or vice versa.

• Inputs for these decisions come from various sensors, including those related to the brake pedal and energy sources.

Power Electronics and Motor Types

• Upcoming discussions will cover different types of motors used in electric vehicles, their speed characteristics, and applications.

• An overview of power electronics topologies utilized in electric vehicles will also be provided.

Charger Control Systems

• Charger control is part of battery management systems but is categorized separately for clarity.

• Onboard chargers are integrated into the vehicle, converting AC to DC for battery charging directly within the vehicle.

Offboard vs. Onboard Chargers

• Offboard chargers contain all conversion circuits externally at charging stations; only the battery remains inside the vehicle.

• Each type has its advantages: offboard chargers are typically used for high-powered vehicles due to reduced costs and weight.

Battery Management Systems (BMS)

• BMS monitors critical parameters such as cell voltage, current flow, and temperature to manage battery discharge and charge safely.

• Discussions will include sensor requirements for measurements like voltage estimation and state of health computation.

Safety Compliance and Communication Protocols

• Safety compliance with ISO standards (e.g., ISO 26262) is crucial but not deeply covered; awareness is encouraged.

• Common communication protocols like CAN are essential in electric vehicles; a session will focus on bus protocols related to EV infrastructure.

Embedded Controller Programming Demonstration

• A demonstration using STDM microcontrollers will illustrate how embedded controllers handle data transfer within EV systems.

Block Diagram Overview of EV Embedded Systems

• A block diagram illustrates various computations occurring within electric vehicle embedded systems, highlighting multiple functions grouped by categories.

• In an EV company setting, each function represented in the block diagram would typically be managed by dedicated teams rather than a single academic approach.

Hybrid Electric Vehicles Overview

Introduction to Hybrid Electric Vehicles (HEVs)

• Hybrid electric vehicles utilize two energy sources: an internal combustion engine and a battery for electrical power.

• There are two main types of HEVs: standard hybrid electric vehicles and plug-in hybrid electric vehicles, with the latter allowing batteries to be charged via external outlets.

Electrical Aspects of HEVs

• The discussion focuses on the electrical components, particularly embedded controllers that play a crucial role in managing vehicle functions.

• Battery packs consist of numerous cells arranged into modules, strategically placed to maintain system stability.

Battery Management Systems

• Managing battery packs involves digital controllers; microcontrollers are essential for monitoring and controlling battery performance.

• Cells within the battery pack are connected in series and parallel configurations to meet voltage and current requirements, typically operating on a 400V DC bus.

Cell Monitoring

• Each cell is monitored by cell monitors that measure voltage, charge levels, and temperature. This data is relayed to the microcontroller for decision-making.

• The microcontroller manages power discharge and safety measures, including temperature control through circulating coolants.

Embedded Controller Functionality

Data Collection Process

• Embedded controllers require data from various vehicle parameters such as speed, battery status, and operational aspects like headlights or infotainment systems.

• Sensors play a vital role in this data collection process; they must be rugged due to the challenging environments in which electric vehicles operate.

Electric Vehicle Sensors and Data Processing

Overview of Electric Vehicle Sensors

• Normal sensors used in electric vehicles (EVs) must be rugged for reliable operation, providing critical data on operating conditions.

• Various types of sensors include voltage, current, temperature, speed, and torque sensors; these help monitor essential vehicle parameters and auxiliary functions like obstacle detection during reverse driving.

Data Collection and Processing

• Collected data needs processing; this involves using both digital and analog sensors to gather information about the vehicle's status.

• Digital sensors provide binary outputs (e.g., door locked/unlocked), while analog sensors require conversion to digital format for processing by embedded controllers.

Analog to Digital Conversion

• Analog-to-digital converters (ADCs) are crucial for transforming analog signals into a digital format that controllers can process.

• ADC selection is important as different applications may require varying conversion speeds; some actions may tolerate delays while others need rapid responses.

Control Algorithms and Actuators

• Once data is processed, control algorithms determine necessary actions based on the collected information; these algorithms depend on the specific control functions defined for the EV.

• Actuators execute control actions by providing outputs such as motor control or wiper operation, ensuring that the vehicle responds appropriately to sensor inputs.

Communication Challenges in Embedded Systems

• Communication within an EV faces challenges due to electromagnetic interference (EMI), which can distort signals traveling through electrical wires.

• The Controller Area Network (CAN) protocol helps mitigate communication issues by ensuring proper cable shielding and robust bus protocols.

Design Considerations for Electric Vehicles (EVs)

Data Storage in EV Controllers

• The discussion begins with a question about data storage in electric vehicles, clarifying that the data is not classified as "big data" but pertains to vehicle operational parameters.

• Typical microcontrollers used in EVs have sufficient memory (megabytes) to handle the required data without needing extensive storage solutions.

Electromagnetic Interference

• The speaker explains electromagnetic interference caused by current-carrying conductors, which generates magnetic fields affecting signal wires carrying electrical pulses.

• This interference can impact the performance of sensors and communication within the vehicle's systems.

Sensor Management and Memory Requirements

• Despite having numerous sensors, the existing memory in controllers is adequate for storing sensor status and information; there are options to expand memory if necessary.

• Future discussions will address specific sensors encountered in EV environments, aiming to clarify any remaining doubts regarding sensor management.

Key Applications of Embedded Systems in EVs

Battery Management

• The primary focus for embedded engineers includes sensing, data collection, processing, and actuation related to battery management.

• Essential parameters such as voltage, current, and temperature must be monitored to control operations like charging/discharging and cell balancing.

Powertrain Control

• Powertrain control involves delivering power from controllers to motors while managing torque production through power electronic converters.

• Thermal management is crucial due to lithium-ion cells' sensitivity; physical temperature sensors monitor battery packs for effective cooling decisions.

Research Opportunities

• There are potential research areas focusing on thermal management using machine learning algorithms to predict battery pack temperatures based on charge/discharge cycles.

User Interface and Infotainment Systems

• While less critical than other functions, user interface design enhances customer comfort; modern cars feature advanced monitors with various interfaces managed by embedded controllers.

Advanced Driver Assistance Systems (ADAS)

Potential Development Areas

• Current commercial applications primarily operate at levels one and two of ADAS; opportunities exist for developing higher-level systems (three through six).

Future Discussions

• Upcoming sessions will focus on foundational topics while allowing room for discussions on advanced ADAS developments if participants express interest.

Summary of Upcoming Sessions

• A brief overview indicates that future classes will summarize previous content while introducing new topics relevant to embedded systems in electric vehicles.

Energy Management in Embedded Controllers

Overview of Energy Management Systems

• Discussion on the functions performed by embedded controllers, particularly focusing on energy management and performance.

• Importance of understanding both the energy source and load requirements for effective energy management in systems like electric vehicles (EVs).

Power vs. Energy in Electric Vehicles

• Distinction between power and energy: power is crucial for acceleration/deceleration, while energy relates to distance traveled and duration of operation.

• Emphasis on managing both parameters effectively within EV applications.

Regenerative Braking Concept

• Introduction to regenerative braking as a method to recover kinetic energy during deceleration, converting it back into electrical energy for storage.

• Highlighting the role of embedded controllers in executing these operations to enhance overall vehicle efficiency.

Safety and Reliability Considerations

• Embedded controllers also manage safety and reliability aspects within EV systems, ensuring robust performance under various conditions.

Hybrid Braking Systems

• Explanation that regenerative braking alone may not suffice; hybrid braking systems combine regeneration with mechanical brakes for improved reliability.

Future Directions in Autonomous Driving

Potential Developments

• Mention of future opportunities in autonomous driving technology, integrating machine learning and artificial intelligence.

Upcoming Sessions Focus

• Preview of forthcoming discussions centered around embedded controller architecture and peripheral functions necessary for control decisions.

Battery Management Systems

Key Components

• Overview of essential sensors used for measuring voltage, current, temperature, etc., critical for battery management.

Control Mechanisms

• Discussion on controlling over-voltage, preventing deep discharging, avoiding thermal runaways, and estimating state-of-charge as vital functions managed by embedded controllers.

Understanding Embedded Controllers and Sensors in Automotive Systems

Overview of Battery Management and Sensor Utilization

• Discussion on how to leverage health data to enhance battery life and vehicle range through sensor data collection.

• Introduction to various sensors, including time-of-flight sensors for obstacle detection, highlighting their relevance in automotive applications.

Practical Applications with Arduino and Industrial Controllers

• Mention of hands-on sessions using Arduino controllers, though noting their limited industrial application.

• Transition from Arduino to industrial-grade controllers like STMicroelectronics STM32 series and Texas Instruments C2000 for motor control.

Focus on Hall Effect Sensors

• Emphasis on the importance of Hall effect sensors in controlling motors such as BLDC, PMSM, and SRM within power electronic drives.

Upcoming Classes and Hands-On Projects

• Outline of upcoming classes focused on embedded controllers, aiming for students to develop systems that manage core functions or auxiliary features.

• Example project idea: implementing a time-of-flight sensor in infotainment systems for track navigation via hand gestures.

Simulation Environment and Software Tools

• Clarification that this week's focus will be on simulation environments rather than direct hardware implementation.

• Discussion about the use of open-source platforms for practical learning experiences.

Limitations of Proprietary Software

• Explanation regarding the non-use of MATLAB due to its proprietary nature; emphasis on accessibility issues among students.

Embedded Linux Considerations

• Acknowledgment that while embedded Linux is crucial for automotive systems, there won't be enough time to cover it comprehensively during the course.

Programming Environments: Text vs. Graphical Language

• Introduction to programming STM32 controllers using STM Cube IDE; mention of graphical programming tools from Altera for C2000 controls.

Physical Learning Experience in Vehicle Design

• Assurance that physical classes will include hands-on experience with actual vehicles, enhancing understanding of components' contributions to performance.

Conclusion and Open Discussion

• Invitation for questions or feedback before concluding the session; mention of potential follow-up regarding VTO diary submissions.

Overview of Development Boards and Class Structure

Class Format and Requirements

• The upcoming sessions will include both online and offline classes, with offline classes aligned with previous online discussions. No installations are necessary for participation; a Gmail account is sufficient for using Tinkercad.

Development Boards in Use

• The primary development boards to be utilized include STMicrocontrollers (STM32 based), Arduino boards, and C2000 Delfino architecture boards. These selections cater to various project needs.

Focus on Simplicity

• While there are dedicated development boards for automotive embedded systems, the course will focus on simpler hardware options. Participants are not required to purchase any equipment unless they have entrepreneurial aspirations.

Microcontroller Specifications

• The typical operating frequency of the microcontrollers ranges from tens of megahertz (40-60 MHz), varying by board and manufacturer. This information is crucial for understanding project capabilities.

Project Assignments and Support

• Project assignments will be provided later in the week, likely in the form of problem statements. Students can seek assistance through designated resources if needed, emphasizing collaborative learning within the course structure.