Design, Development and Testing of Electronic Control Unit Prototype in an Electric Vehicle

An Electronic Control Unit (ECU) acts as a vehicle's the central hub, managing functions through microcontrollers that interpret sensor input and ensure smooth operation. Over 50 microcontrollers govern the operation of low-voltage components like indicators, horns, regenerative brakes, air conditioners, power windows and airbag deployment to monitor control, and enhance diverse aspects, such as engine and motor modules' suspension, powertrain, transmission, brakes, and body functions. This paper delves into the hardware design of an electric vehicle powered by a 48V Lithium Nickel Manganese Cobalt Oxide (Li-NMC) battery. To efficiently utilize this voltage, a buck converter steps it down to 12V for the low-voltage system, with voltage regulators further reducing it to 5V for the microcontroller board's operation. Inputs from buttons like start, brake, charge, accelerator, forward, and reverse are processed by the microcontroller board and Motor Controller. They, in turn, control various LED pins to indicate different states of the car system. The system, designed for an all-terrain vehicle, underwent rigorous testing with a Brushless Direct Current (BLDC) motor, achieving 45 km/hr and 5.16 m/s
²
acceleration. The implementation uses an Arduino board and C language to enhance the vehicle functionality by enabling user interactions, such as starting the car, applying brakes, charging, and controlling acceleration, all while providing clear visual feedback through LED indicators. This paper exemplifies the potential of readily available microcontroller applications for EVs and provides a forward looking vision for an all-terrain four-wheel electric vehicle, showcasing the energy-efficient utilization of low-voltage systems through readily available electronic circuit boards.