Zonal Architecture – The Electronic/Electrical System for the Vehicles of Tomorrow

Over time, this has resulted in an increasingly complex network of more than 100 ECUs in a single vehicle. With the so-called zonal architecture, this complexity can be significantly reduced. The key lies in the shift from a logical transformation into a scalable and centralized Software Development to build the bridge to perform OTA updates for a Software Defined Vehicle and a physical transformation with an outcome of zonal aggregation and ECU clustering. For instance, these zone controllers are installed in the edge areas of the vehicle and manage the devices within their respective zones, such as front- and rear lighting, actuators, suspension and doorsystems . Instead of each component running its own software, the zone controller acts as a hub, responsible for power distribution and data communication. The zone controllers are connected to a central high-performance computer that manages the different vehicle functions – while the zone controllers execute them. This shift replaces hundreds of point-to-point cables with a simpler, more manageable zonal layout. As a result, weight optimization, design clarity and system efficiency are significantly improved to build up real time processes, on time over the air updates to secure the system.

• Reduced complexity and lower weight of the wiring harness
• Lower material and assembly costs
• Improved scalability – new functions can be added or modified via software
• Simplified development and over-the-air (OTA) updates thanks to centralised software control
• Easier coordination of functions – the central computer issues a single command, executed by the relevant zone controllers

Ethernet as the Central Communication Standard

For seamless, cross-functional data exchange between zones, robust and high-speed communication networks are essential. These include multi-gigabit Ethernet and SerDes (serializer/deserializer) applications, capable of transferring the huge volumes of real-time data generated by modern sensors, cameras, and radar/lidar systems. However, maximum data rates are not always required: CAN/CAN FD and CAN XL transmits up to 20 Mbit/s, sufficient for connecting low-bandwidth devices such as headlights, indicators, or door locks. The standard utilizes the mature bus communication ecosystem – including time synchronisation and error correction – but without the overhead of higher-speed Ethernet, such as 100BASE-T1 or gigabit Ethernet.

Transition to 48 V Architectures

Moving from traditional 12 V systems to 48 V architectures reduces current levels, minimises resistive losses, and improves overall efficiency in power distribution. This enables better thermal management and supports scalable high-performance computing platforms, in line with the requirements of SDVs and electrification.

Smart Switches in Power Distribution

Zone controllers do not just route data; they also distribute power to the components in their zones. They therefore play a critical role in system safety and diagnostics. Smart switches provide far more than basic circuit protection. They allow for voltage and current monitoring on every channel, support safety standards such as ASIL B and ASIL D, and offer fail-safe and fail-operational modes. Even in case of faults, the function can be maintained. For example, in the event of a malfunction, a smart switch can reduce power, isolate the fault, or switch to a safe fallback mode instead of completely shutting down critical systems such as headlights. This level of transparency and control is essential for higher levels of automated driving.

To effectively prevent cyberattacks, new software-level security measures must be implemented. High-performance firmware for hardware security modules anchors security functions directly onto the chips of vehicle computers and zone controllers, according to ISO 26262 safety- and ISO/FAE 21343 security standards. Automotive-specific post-quantum cryptography already provides protection today against future threats posed by quantum computing.