Safety and efficiency: key aspects of power distribution

The zone controller is responsible for the intelligent distribution of energy and data within a specific zone of the zonal architecture. Both the development and the provision of the product for customers are carried out in collaboration with Valeo. As Tier 1, Valeo takes care of communication and data processing as well as the production process. LEONI, in turn, is responsible for the safe and reliable power supply for all applications within the zone. This is the basis for an innovative and optimized E/E architecture.

The facts at a glance:

• Enabling an optimized E/E architecture 
• Synergy and integration approach for energy and data distribution, enabling zonal control 
• Cost savings by reducing the number of functional control units and optimizing the vehicle electrical system in terms of complexity, weight and installation space
• Enabling a secure power supply for safety-relevant functions such as steering and brakes and data communication for ADAS functions in the vehicle

The intelligent power distribution boxes are called iPDS and iPDM and stand for Intelligent Power Distribution Switch and Intelligent Power Distribution Module. These devices ensure the power supply for safety and non-safety-critical vehicle functions in the 12, 24 and 48-voltage network and thus create the basis for automated driving functions. The switch is designed for interrupting a load, while the module can operate different loads in parallel.

The facts at a glance: 

• Cost savings through on-board power supply optimization in terms of complexity, weight and installation space
• Easy integration into existing vehicle electrical system architectures
• Complete diagnostic coverage for automated driving

In an accident situation, all power lines must be switched off to avoid short circuits that could lead to burning cables or sparks, which in turn could ignite gasoline. Important functions such as the door opener and hazard warning lights remain active. The trigger for the switch-off comes from the airbag control unit. This ballast box is mounted directly on or near the battery. It can be equipped with pyro fuses for rapid current cut-off and with main fuses to protect the cables in the event of a slow short circuit. In addition, a relay can be integrated to cut off unused power in the event of an accident or a low battery. In this application, a compact customized LEONI multiple fuse is used instead of individual fuses. Due to the limited space available, the back-up fuse boxes are usually customized.

The facts at a glance:

• Scalable in size and performance
• Based on busbars or hard-wired, depending on requirements
• Integration of LEONI multiple fuses
• Developed as a system with integrated power connections
• Intelligent thanks to integrated circuit breakers

Unlike the pre-fuse box, which controls entire areas, the power distribution box is only responsible for certain power consumers. Placed in the vicinity of these consumers, they secure the power supply in the medium or low current range and switch electrical sub-networks such as fans, glow plugs and so on. The internal power distribution is carried out either via cables, busbars or PCB technology and connects fuses, diodes and relays. The cable set can be connected to the box via plug-in or screw connections. The number of switched and fused outputs can be adapted to individual customer requirements. In some cases, a microcontroller with e.g. LIN bus takes over the switching task of the relays and the status diagnosis.

The facts at a glance:

• Scalable in size and performance
• PCB-, busbar- or hardwired-based depending on requirements
• One-piece or modular design
• System design with wiring harness connectors
• Intelligent power switching or load diagnostics