Research on Zonal Architecture: Smart Actuators (Micro-motors) and Application Trends in Sub-scenarios, 2026
Smart Actuator and Micro-motor Research: Under Zonal Architecture, Actuators Are Developing towards Edge Computing, 48V, and Brushless Motors.
The core components of automotive zonal architecture mainly include: a central computing unit, zone controllers, edge nodes (sensors and actuators), high-speed communication networks, and power distribution modules, as well as software and network management systems.
Differing from the traditional split architecture of micro-motor + gearbox + ECU, a smart actuator integrates microprocessor, communication interface, drive circuit, and position feedback sensor directly with the motor actuator, becoming a "smart terminal" with local computing, status monitoring, fault diagnosis, communication interaction, action execution, and millisecond-level response capabilities. It can greatly reduce the number of cable connections between traditional ECUs and motor actuators, achieving intelligent and precise control of various vehicle functions. In terms of hardware composition, smart actuators integrate edge perception, local computing, communication, and drive.
Edge Perception: Automotive actuators themselves usually do not require sensors to directly drive their basic functions. However, in the overall vehicle control system, actuators and sensors work closely together, serving as the core of realizing the "closed-loop control" of automotive electronics. Through "sensor feedback + actuator adjustment", sensors convert physical quantities into electrical signals and feed them back to the ECU. The ECU dynamically adjusts control commands to the actuator by comparing the "target value" and "actual value", enabling closed-loop control.
Edge Computing: In the evolution of the automotive EE architecture from the traditional distributed, domain-centralized to "central computing + zonal control" architecture, local computing of actuators has become a key technology development direction. There are two main technology paths for local computing of actuators: remote-controlled edge nodes (actuator does not contain MCU) and smart edge nodes (motor control algorithm is deployed to the actuator side).
Remote-controlled Edge Nodes: Through the remote control protocol (RCP), the control logic of edge nodes (lights, doors and windows, sensors, etc.) is migrated from the local MCU to the central computing platform or zone controllers. This allows edge nodes to only retain basic I/O drive functions and become remotely accessible peripherals.
Smart Edge Nodes: These nodes further offload some computing tasks from the ZCU to the actuator closer to physical actions. A lightweight MCU or dedicated processing unit is retained at the edge node, and the actuator module includes an MCU, drive circuit, sensor interface, etc. Such a smart actuator has certain local data processing, decision, and control capabilities, and can independently complete real-time closed-loop control (e.g., motor PWM control, current monitoring, anti-pinch algorithm execution), without completely relying on instructions from the central or zone controller. Deploying motor control algorithms to edge-side actuators offers advantages such as faster real-time response, sharing computing power from the central computing platform/zone controller, and functional safety isolation.
Highly Integrated Motor Drive SoC: The local computing capability of smart actuators depends on the advancements of underlying chip technology, and requires highly integrated dedicated drive and control chips to provide the power and control foundation for local computing of actuators. Fully integrated embedded motor drive SoC products integrate MCU, power management, CAN/LIN communication interfaces, gate drive, operational amplifier, and other functions into a single chip. They can complete the full process of motor control, communication, and protection of smart actuators without additional peripheral chips. Highly integrated motor drive SoCs are mainly used for controlling various actuators, thermal management pumps, fans, etc., providing underlying technical support for the mechatronic evolution of intelligent electric vehicles.
Edge Communication: For each edge node under a domain controller, due to different application functions, some non-real-time applications have low requirements for data transmission. Considering application needs and costs, traditional bus communication technologies such as CAN/CAN FD/FlexRay will still serve most low-speed communication networks in automobiles. However, under the zonal architecture, the competition in 10M transmission rate applications will be fierce, mainly between 10Base-T1s and CAN-XL.
Edge Micro-motors: Micro-motors are widely used in vehicle body, intelligent cockpit, chassis, thermal management, and other fields. Examples include window regulators, seat adjustment motors, seat ventilation and massage systems, electric door drives, vehicle display screen adjustment structures, automatic windshield wipers, electronic pumps, electronic valves, electric air outlets, and other automotive end adjustment mechanisms. These enable precise control of various vehicle parameters. With the development of new energy vehicle intelligence, the demand for micro-motors will continue to grow due to more new functions and better comfort. Micro-motors are gradually developing towards 48V motors, brushless motors, and mechatronics.
Zonal Control Architecture Spawns the Application of Smart Actuators.
The development of zonal control architecture will further facilitate the application of smart actuators. In the zonal control stage, ZCU serves as the power distribution center, communication gateway, and I/O control center in the zone. It has a central computer at the upper level and multiple actuators at the lower level. If the underlying drive control of all actuators (e.g., micro-step control of stepping motors, commutation logic of brushless motors, and position closed-loop feedback) is completed by the ZCU, it will consume a lot of real-time computing power and increase the software complexity and code size of the ZCU. In terms of simplifying wiring harnesses, since the ZCU still needs to directly drive a large number of motors, the wiring harness problem is only transferred from the center to the zone and not fundamentally solved. This is uneconomical for the zonal control architecture that pursues high efficiency and simplicity, and also violates its original intention of "simplifying software management".
Therefore, the new architecture requires offloading a large number of simple execution control functions to the "endpoints" close to the actuators. Edge nodes are required to have basic communication functions and certain local computing capabilities to realize single sensor signal processing or execution actions. This spawns the demand for actuators with higher integration and local intelligence to simplify wiring harnesses, reduce costs, and improve system reliability. Smart actuators will become a perfect supplement to ZCU in the zonal control architecture. In addition, as the iteration of automotive functions accelerates, under zonal control architecture, new functions only need to add smart actuators in the corresponding zone and connect them to the existing network, without needing to modify the hardware architecture, or rewire extensively, enhancing system flexibility and scalability.
Smart actuators are widely used in body, chassis, thermal management, powertrain, and other domains, involving electronic air outlets, electronic water valves/expansion valves, hidden door handles, electric charging port covers, smart seat adjustment, AGS active air intake grilles, vehicle rotating/lifting display screens, adaptive front-lighting systems (AFS), electric power steering, brake actuators, and active suspension.
In the case of Nidec's EPS PP integrated product, this product integrates ECU controller and EPS motor, which can replace split motor control and provide auxiliary output for the vehicle steering system.
Bumpy Roads: Nidec's EPS PP will perform torque compensation by identifying the torque fed back to the sensor from the road surface, making driving stable and direction control easier.
High-speed Roads: Nidec's EPS PP will collect vehicle speed signal information and provide smaller steering torque at high speeds, making the direction more stable.
Parking or Driving on Low-speed Roads: After Nidec's EPS PP obtains low-speed vehicle speed signal information, it will provide larger steering torque, making the steering smoother and facilitating parking or U-turns.
Under 48V Low-voltage Power Supply Architecture, High-power Actuators Tend to First Upgrade to 48V Motors.
The conversion from a 12V to a 48V automotive system has a significant impact on actuators. Traditional 12V motors, relays, and other components cannot be directly used in a 48V environment and need to be redesigned in terms of insulation level and voltage resistance. In addition, the number of turns of 48V motors also needs to be adjusted. From the perspective of industry chain maturity, the maturity of actuator and load products like 48V motors is relatively low, and the matching with PMIC needs to be optimized.
The upgrade from the 12V to the 48V power distribution architecture is mainly divided into two stages: the first stage is the coexistence of 12V and 48V electrical networks, and the second stage is the full 48V electrical network. At present, it is in the stage where 12V and 48V electrical networks coexist, and 12V/48V loads are mixed in the controller area.
Currently, not all actuators need to be upgraded to 48V, mainly based on power size and cost-benefit analysis. Only when the load power is at least 50W can 48V show obvious advantages. Below 50W, the advantages of the 48V architecture are not obvious. Therefore, in the upgrade to 48V motors, high-power loads with high power consumption are affected first. With the gradual reduction of costs and the improvement of system efficiency, the application proportion of 48V motors will continue to expand.
First Upgrade High-power Loads: High-power loads (usually referring to 50W or 4A and above) are the priority for upgrading because they can significantly reduce wire diameter, lessen weight, and improve efficiency. For example, cooling fans are generally 350W, blowers are about 250W, and water pumps are 120W. There are also steering motors, active suspension motors, brake motors, electric compressors, etc. Many of these motors have very high power and are very necessary to switch to the 48V system.
Medium-power 12V Loads Gradually Convert to 48V: For medium-power loads such as seat motors, wiper motors, and lighting systems, the 48V system can improve motor power output, thereby enhancing a vehicle's driving stability and safety in severe weather. In addition, it can more effectively manage power demand and reduce system complexity.
Some Low-power Loads May Maintain 12V: For some low-power loads, generally a few watts, the benefits of reducing wiring harness costs and improving efficiency by converting to 48V are not obvious. On the contrary, it increases a lot of costs, and the cycle of reliability test verification such as salt spray, EMI, static electricity is greatly increased. Therefore, some low-power loads maintain 12V unchanged and are driven through internal voltage conversion, which is simpler.
Taking Johnson Electric's 48V electric fan as an example, the cooling fan assembly module can meet the requirements for air volume, power, efficiency, weight, noise and vibration, carbon dioxide emission, etc., with the design of single-motor/dual-motor cooling fan assembly module, forward-curved/backward-curved blade design, brushed/brushless motor solution, etc.
Brushless Motor Platform: Full power coverage of 100W-1500W, 12V and 48V; long service life, high efficiency, reliability; lightweight; with/without PCBA.
Brushed Motor Platform: Power coverage of 80W-500W; long service life and reliability; optimal balance of weight, packaging, cost, and efficiency; stall protection.
In the case of Marelli's fully active suspension electromechanical actuator solution, the physical hardware of the solution consists of four electromechanical actuators. Each actuator is composed of a 48V brushless motor and a high-speed ratio reduction gear, connected to the suspension arm, and can actively move the suspension. The motor is controlled by a dedicated inverter which receives stroke targets from the central unit hosting the vehicle dynamics software.
The system is powered by a 48V circuit integrated into the vehicle power grid and ensures correct energy flow. The central electronic control unit controls each actuator via electronic hardware and dedicated software. The software monitors various signals, such as acceleration, suspension stroke, steering angle, main propulsion device parameters, brake pedal, and torque demand, and predicts the action that each actuator must apply to the suspension arm to set the appropriate reaction force. The drive unit integrated in the actuator receives the force demand from the central ECU and uses embedded algorithms to calculate parameters (target current) to drive the actuator's motor.
Brushless DC Motors Gradually Replace Brushed Motors and Become the First Choice for Automotive Motors in High-performance Vehicle Models.
Brushless DC motor (BLDC) is a DC motor that uses electronic commutation and applies an electronic controller to replace traditional DC motors with carbon brushes. Because there are no brushes in the brushless DC motor itself, its service life is much longer than that of brushed DC motors. Moreover, without the friction resistance of brushes, it offers higher conversion efficiency and low noise advantages. In addition, brushless motors can cooperate with encoders to achieve more precise control of speed and position loop. Brushless DC motors (BLDC) have become the first choice for automotive motors thanks to their high efficiency, long service life, and low noise characteristics. The addition of intelligent control algorithms makes motor operation more precise and smoother.
However, the internal structure of brushless DC motors is relatively complex, and the drive circuit and algorithm are correspondingly more complex, so their cost is higher than that of brushed DC motors. At present, they are mainly used in mid-to-high-end vehicle models with high requirements for cabin comfort, chassis, and thermal management performance.
From the perspective of suppliers laying out automotive brushless motors, mainstream Chinese and foreign motor suppliers have relatively complete product layouts of brushless DC motors, covering applications from body domain and chassis domain to thermal management domain, such as EPS, SBW, EMB, air suspension, electronic water pumps, electronic oil pumps, electric fans, windshield wipers, and seats.
For example, the BL3040 inner rotor brushless DC motor launched by Topband Motor is specially designed for the screen rotation system of new energy vehicles. In addition to vehicle ceiling screens, it can also be used for center console deflection screens, center console lifting screens, and other applications. This series of motors features energy conversion rate up to 75%, low cogging torque and large torque output, low noise, and vibration.
For example, Brose’s electric long seat slide also adopts a self-developed brushless motor. Compared with ordinary motors, the brushless motor ensures the stability of seat operation through motor control, bringing more sensitive precision. It can effectively eliminate the noise generated by the contact between the brush and the rotor when traditional motors are running. It brings soft start-stop, anti-pinch, easy entry and other application functions for seat adjustment.