Next-gen ECU: Pioneering the Future of Electrical Architecture

Rimac Technology (RT) is striving to be at the forefront of reshaping the electrical
architecture landscape in modern vehicles, pushing boundaries through innovation. To address the growing complexity of automotive systems, RT has transitioned from distributed electrical designs to centralized, cross-domain architectures powered by high-performance vehicle computers. This innovative approach eliminates the need for numerous individual control units (ECUs), integrating
power distribution and computational capabilities into fewer, centralized units. The result is a streamlined system architecture that enhances reliability, security, and scalability.

The Vision and Ideation: Redefining Possibilities

In the wake of delivering the Rimac Nevera with over 20 ECUs per vehicle, RT's engineers envisioned a bold transformation: reducing complexity by creating a single, powerful ECU platform capable of managing the most intricate vehicle functions. This platform was designed to be scalable, ensuring tailored solutions for various OEM requirements. The "Domain ECU" concept emerged from extensive data analysis across automotive sectors, culminating in a specification that sets new benchmarks for performance and versatility.

Domain ECU Core Specifications

PROCESSOR

• Multicore architecture delivering up to 16,000 DMIPS @ 800 MHz.
• Ample internal and external memory to support complex, multifunctional operations.

POWER SUPPLY

• Voltage range: 8.0–16.0 V DC, supporting 60A nominal load, Flexible external sensor support.

I/O

• Configurable input stack with WAKE UP, digital, and analog inputs to ensure versatility.
• Scalable outputs including digital outputs, and power outputs optimized for diverse functions.

COMMUNICATION PROTOCOLS

• Support for CAN FD, LIN, Automotive Ethernet, and SENT Protocol.

SAFETY & SECURITY

• Adherence to the highest automotive safety standards and regulations.

This robust platform was designed to host applications across various domains, including Vehicle Dynamics Control, Energy Management, Charging Control, Thermal Management, and Body Electronics.

Overcoming Challenges through Innovation

Adhering to stringent automotive standards like EMC compliance while supplying a 60A load presented a significant challenge. Through iterative hardware design, advanced simulations, and rigorous fault tolerance analysis, Rimac’s engineers ensured the ECU met performance and regulatory requirements.

Achieving optimal thermal performance without compromising reliability demanded innovative materials and precise simulations. By refining the design during the prototyping phase, the team ensured the ECU could deliver peak performance consistently over extended use.

Production-Ready Design

Transitioning to production required meticulous refinement of manufacturing processes to guarantee precision and reliability. Each ECU underwent extensive testing to ensure compliance with rigorous standards before deployment in high-performance vehicles.

The production ECU specifications achieved include:

PROCESSOR

• 8x Arm Cortex®-R52 cores @ 800 MHz (dual 4-core clusters).
• Memory: 32 MB Internal RAM, 19MB internal SRAM with ECC, 512kB internal flash, and 2GB LPDDR4 external SDRAM.

POWER SUPPLY

• Voltage range: 8.0–16.0 V DC, 60A nominal/125A peak (10s).

INPUTS & OUTPUTS

• Expanded I/O capabilities with configurable digital and analog options (30+ inputs and 35+ outputs including power outputs).

COMMUNICATION

• Multiple interfaces including 7x CAN FD, 4x LIN, 100B-T1 Automotive Ethernet.

SAFETY & COMPLIANCE

• ISO26262 ASIL-D, AUTOSAR compliance, and IP67 protection.

Results: Delivering Breakthrough Achievements

The production ECU was developed for a cutting-edge hypercar, replacing over 20 ECUs with just three centralized units, handling around 70% of the vehicle's complex functions. Rimac Technology’s unified ECU platform not only simplified the vehicle's E/E architecture but also significantly enhanced security, reliability, and scalability.

This breakthrough marks a paradigm shift in E/E architecture for software-defined vehicles, setting a new standard for innovation. Rimac Technology’s domain/zonal ECU is one of the first-to-market solutions, offering streamlined, efficient, and scalable mobility solutions.