In current automotive electrical design practices, simulation and functional verification of the Electrical Distribution System (EDS) at the design stage are largely absent. Typically, the validation of controller behaviour and EDS wiring is performed only during HIL, SIL, MIL, prototype testing, or physical vehicle trials, often revealing issues late in the development cycle. This delay leads to costly redesigns, prolonged timelines, and increased chances of failure during vehicle integration. Therefore, there is a critical need for an early-stage simulation methodology that ensures robust EDS and controller design, enabling "first-time-right" readiness at the design stage itself.
The proposed simulation framework introduces a function mode-based structural approach, where individual vehicle functions are mapped to their corresponding electrical circuits within the vehicle’s wiring system. Resistance values are allocated to specific paths depending on the active function or operational mode. A function-specific truth table governs the activation logic, enabling the controller to dynamically assign resistance paths during simulation. This proactive verification ensures that electrical loads, power distribution, and switching logic are accurately validated during the design phase, significantly reducing production-time issues and ensuring a seamless transition to manufacturing.
The simulation environment has been developed using Capital Logic, enabling detailed modelling of both the controller’s functionality (mode-behaviour) and the electrical network (mode-structure). Unique techniques such as active resistance assignment, dynamic power flow diagrams, and function-driven truth tables have been employed to enhance simulation fidelity. In addition to function-based simulation, the methodology also includes the mapping and evaluation of probable failure conditions, strengthening the robustness of the design against real-world scenarios. By verifying critical functional behaviour and potential failure modes digitally at the design stage, this approach ensures higher reliability, reduced rework, and accelerated product development cycles, setting a new benchmark for EDS and controller validation in the automotive domain.