The Development of A Turnkey Body Electronic Systems for Niche Vehicles

This case study showcases how Embed can deliver an off-the-shelf solution to standard body electronics functionality of a vehicle to assist in passing IVA / ECWVTA regulations, such as indicator, wiper and lighting control.

We know that when you’re designing a new vehicle the fun parts are the aesthetics and performance. Making your vehicle beautiful and making it go fast! What we have discovered is that the body's electronics are often left until the end and are far from fun. This means it will cost you a lot more and will inevitably make your vehicle heavier due to the electrical harness. It can also mean making compromising modifications to your beautifully designed vehicle.

What we have done is take all of this annoyance away from you. We have created a modular body electronics system that can be easily implemented into a vehicle platform. The functional behaviour has been designed around the UK Individual Vehicle Assessment (IVA) to allow road-worthy operation, with standard features such as lane-change indication and variable wiper speed control. We have designed it so that there can be multiple power distribution modules handling all of your electronics which are controlled via CAN using our E400 ECU. Using this architecture greatly reduces the wiring harness, and therefore the weight of your vehicle. There are only three wires (CAN pair, plus battery feed) to distribution modules that are placed at the front and rear of the vehicle, for example.

The above image shows an example ‘full fit’ layout, consisting of:

Front PDM (Power Distribution Module)

• – 1 – Indicators (front, left)
• – 2 – Side Lights
• – 3 – Dipped Beam Headlights
• – 4 – Main Beam Headlights
• – 5 – Fog/Aux Lights (front)
•  – 6 – Indicators (front, right)
•  – 7 – Windscreen Washers
•  – 8 – Wipers (low speed)
•  – 9 – Wipers (high speed)
•  – 10 – Interior/Courtesy Light(s)
•  – 11 – Horn

Rear PDM (Power Distribution Module)

• – 12 – Brake Light (3rd/high level)
• – 13 – Brake Light (left)
• – 14 – Tail Lights
• – 15 – Indicator (left, rear)
• – 16 – Reverse Light(s)
• – 17 – Number Plate Lights
• – 18 – Fog Lights (rear)
• – 19 – Indicator (right, rear)
• – 20 – Brake Light (right)
• – 21 – Rear Wiper (if fitted)

The above configuration uses two 12-slot PDMs, leaving 3 free slots (1 front, 2 rear). This config. is the most robust; providing rear wiper function and separate brake light circuits.

Another example would be the ‘Minimum Road Legal’ fit:

Single PDM

• – 1/15 – Indicators (left)
•  – 2 – Side Lights
•  – 3 – Dipped Beam Headlights
•  – 4 – Main Beam Headlights
•  – 6/19 – Indicators (right)
•  – 7 – Windscreen Washers
•  – 8 – Wipers (low speed)
•  – 9 – Wipers (high speed)
•  – 11 – Horn
•  – 14 – Tail Lights
•  – 17 – Number Plate Lights
•  – 18 – Fog Lights (rear)

This configuration only uses a single PDM as a cost-saving, but therefore forfeits some of the features and redundancy of the first ‘Full’ example.

The final example would be of use for an ‘off-road’ only vehicle and does away with things like number plate light, indicators and wipers:

Single PDU

•  – 2 – Side Lights
•  – 3 – Dipped Beam Headlights
•  – 11 – Horn
•  – 13/20 – Brake Lights
•  – 14 – Tail Lights
•  – 16 – Reverse Light(s)

All the examples above use an off-the-shelf modern Ford steering wheel column switch pack and head/fog light pack. These interface with the E400 over LIN, meaning another reduction in wiring. Making them easy to install and reducing the weight yet again.

Having an ECU in control of your electronics means they can be ‘smart’. You can have ‘lane change’ indicators, meaning a nudge of the stalk will produce a set number of flashes. You can easily meet IVA requirements regarding the operation of certain lights in conjunction with other lights (e.g, fog lights can only be on with at least sidelights active too). With an external sensor, you can have a ‘heavy braking warning’ by flashing the hazard lights. Specialist features can be developed, such as rain lights or ‘flash-to-pass’ headlights for racecar applications. You can have outputs for beacons, winches, lifts. Whatever your needs, we can accommodate.

The E400 can use temperature sensors to turn fans on at pre-set limits. It can take inputs from other units, such as an alarm/immobiliser (for example, you could turn the front fog and interior lights on when the car is unlocked).

With the inclusion of our UDS Blockset, you can easily configure parameters such as indicator flash speed, intermittent wiper intervals and heated rear window latch time. It also allows you to retrieve system diagnostics if there’s an issue.

Further extensions to the Embed BCM can include items such as a digital instrument cluster to display connected data, or a telematics unit to provide off-board data recovery and diagnostics, remote start and climate features and even stolen vehicle tracking capabilities. Why not add a small auxiliary screen and have all your door, window and HVAC controls in 1 small, neat control?

Whatever your needs, don’t hesitate to contact us and see how we can help you get your Niche Vehicle to market faster and lighter.