Issue link: https://iconnect007.uberflip.com/i/1541670
60 SMT007 MAGAZINE I DECEMBER 2025 • Functional safety: Redundant sensing, fault- tolerant software, and ASIL-rated microcon- trollers are essential • Diagnostics and monitoring: Embedded self-checks, sensor health monitoring, and standardized diagnostic messaging, such as Unified Diagnostic Services (UDS), support proactive servicing • Thermal design: Liquid-cooled power mod- ules and split-layer PCB copper planes enable better heat spreading • Electromagnetic compatibility (EMC): Layout strategies, common-mode filters, and shield- ing materials mitigate EMI between control domains Predictive maintenance, enabled by onboard monitoring, real-time analytics, and cloud-con- nected diagnostics will become key in the future. Control units will not only direct motion but help anticipate failure, enabling service before break- downs occur 14 . Additionally, as illustrated in the figure below, system-level reliability progressively increases for these intelligent controls at the core in "layers" from the control hardware itself to predictive intel- ligence. Conclusion As EVs scale in production and diversify in design, the VCU, MCU, and PDU central control systems stand as foundational pillars in the architecture of reliability. Their roles are not passive or isolated. Instead, they serve as adaptive, intelligent agents coordinating propulsion, safety, energy efficiency, and user experience in unison. The path to sus- tainable EV adoption runs through the command centers of these control units, where every signal, switch, and subroutine carries the weight of vehi- cle performance and customer trust. Ensuring their design, manufacturing, reliability, and monitoring is as robust as the mechanical systems is key to delivering EV platforms that perform consistently, safely, and economically over their lifetime. SMT007 References 1. "Energy efficient torque vectoring control," by P. Gruber, A. Sorniotti, B. Lenzo, G. De Filippis, and S. Fallah, AVEC 16: 13th International Symposium on Advanced Vehicle Control, Munich, Germany, 2016. 2. ISO 26262 Functional Safety Standard, Road vehicles – Functional safety, 2018. 3. I-Connect007 image render, November 2025. 4. "Block-Level Concept of Motor Control Unit for EV," Knowledge Base Article, Infineon Technologies, May 22, 2024. 5. "Electrical Vehicle Improvements With a Highly Efficient Traction Inverter Design," Texas Instruments, Application Report SPRADH3, September 2024. 6. "Why EV Makers are Embracing Integrated Electric Drive Units," by N. Palmer, EV Infrastructure News, June 3, 2025. 7. Image from animation at Audi Media Center, Oct. 2019. 8. "High-Voltage Power Distribution Units," Wurth Electronics. 9. "What to Watch When Designing Vehicle Architectures for 800V," Aptiv, Dec. 20, 2023. 10. "How to Meet the Higher Isolation Creepage & Clear- ance Needs in Automotive Applications," by N. Seshan, Texas Instruments Application Report SLLA469, Jan. 2020. 11. Power distribution units, Eaton press releases, Business Wire, June 2021 and March 2024. 12. "Vehicle-centralized, zone-oriented E/E architecture with vehicle computers," Bosch. 13. "Thermal Design and Optimization Methodology for Integrated Power Electronics Modules," by Y.F. Pang, E.P. Scott, J.Z. Chen, and K.A. Thole, Journal of Electronic Pack- aging, Transactions of the ASME, 2005. 14. "A Comprehensive Review on Artificial-Intelligence- Driven Predictive Maintenance in Vehicles: Technologies, Challenges and Future Research Directions," by Y. Mahale, S. Kolhar, and A.S. More, Discover Applied Sciences, 2025. Stanton Rak is principal consultant for SF Rak Company, and co-chair of the APEX EXPO Technical Committee. Reliable power management, from reactive control to predictive assurance. ▼