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In 2023, a leading Tier 1 supplier, working for a renowned German OEM’s highly autonomous vehicle production program, needed a DC-DC power conversion system that could act as a failsafe backup power source. If the main system failed, this unit had to seamlessly take over, ensuring the vehicle could still function. Without it, the vehicle would lose critical power functionality, impacting its ability to turn ON/OFF instantly. This project demonstrated how software-defined intelligence is reshaping the power electronics landscape.
As vehicles become more autonomous, power systems must evolve from passive components into intelligent guardians. The ability to regulate, monitor, and protect power delivery is no longer optional — it’s foundational to safety and performance.
In 2023, several key trends significantly impacted the automotive industry, particularly in the realms of Battery Management Systems (BMS), AUTOSAR standards, and DC-DC converters.
Battery Management System (BMS)
The BMS market saw notable advancements, especially with the rise of electric vehicles (EVs) and hybrid electric vehicles (HEVs). One of the most significant trends was the development and adoption of wireless BMS. This innovation reduces the need for extensive wiring, simplifying installation, cutting costs, and minimizing the risk of wiring errors.
AUTOSAR (Automotive Open System Architecture)
AUTOSAR continued to dominate as the primary software architecture standard in the automotive sector. In March 2023, there was a heightened focus on AUTOSAR Adaptive, which caters to the development needs of autonomous and connected vehicles. This version supports the complex requirements of modern vehicle software systems, enhancing flexibility and scalability.
DC-DC Converters
DC-DC converters in the automotive industry experienced significant improvements with the integration of silicon carbide (SiC) technology. This advancement offers higher efficiency and reliability. Key developments included integration with high-voltage systems and enhanced fast-switching capabilities, leading to better power conversion efficiency in EVs. There was also a strong emphasis on sustainability, with the development of converters that have a low environmental impact and advanced digital features for improved monitoring and control. Increased demand from emerging markets, particularly in the Asia-Pacific region, further spurred innovation and market growth.
The customer, a leading Tier 1 supplier, working for a renowned German OEM’s highly autonomous vehicle production program, needed a DC-DC power conversion system that could act as a failsafe backup power source. They required a partner with expertise in power electronics software, functional safety, diagnostics, and cybersecurity.
The project was highly complex, with 800+ detailed requirements covering power regulation, real-time diagnostics, functional safety, and cybersecurity. It had to meet ASPICE Level 2 certification to ensure it complied with industry standards. To deliver a reliable and fail-safe power system, the Tier-1 partnered with Acsia for their expertise in power electronics software, functional safety, diagnostics, and cybersecurity.
A System Designed for Reliability
The 12V-DC-DC power converter was designed to meet critical operational and safety requirements, such as:
To turn these requirements into a functional, real-world system, Acsia used a structured methodology to translate 800+ requirements into a working system architecture – deconstructing and categorising each function into hardware, software, and operational components, ensuring alignment with safety, performance, and compliance. This ensured that each system function was carefully mapped to its intended role, making implementation efficient and predictable.
AUTOSAR Integration
A critical enabler in meeting these requirements was the integration of the AUTOSAR base software stack. Acsia was chosen for its deep expertise in AUTOSAR configuration, integration, testing, and validation, as well as its ability to handle Functional Safety responsibilities aligned with the ASPICE V model. The scope included:
A custom application layer was developed to manage the key control strategies of the DC-DC converter, including capacitor precharge control and boost-mode activation based on inputs from the BMS. This layered architecture ensured safety, traceability, and platform scalability.
Developing a DC-DC power system isn’t just about regulating voltage – it requires precision, safety compliance, and intelligent fault handling. Acsia worked to ensure that every aspect of the system was designed for stability, security, and resilience.
Fail-Proof Safety
These measures ensured the DC-DC power system was not only operational but also fail-safe, setting a new benchmark for intelligent power management solutions.
The system is capable of:
With automated fault detection, secure communication, and predictive diagnostics, the system set a new benchmark in reliable power management.
In an era where power resilience is mission-critical, Acsia’s work on this project showcased what’s possible when software intelligence meets precision engineering.
Through this project, Acsia’s team gained a comprehensive understanding of Vector tools, such as VTestStudio, DaVinci configurator and developer which are crucial for configuring and testing AUTOSAR-compliant systems. This knowledge is instrumental for future projects that require precise and efficient software and hardware integration.
The project solidified Acsia’s ability to handle stages SYS.2 to SYS.5 and SWE.1 to SWE.6 of the V Model. This includes system engineering, software engineering, and ensuring all components meet the necessary quality and safety standards. This expertise is vital for managing complex automotive projects that involve multiple stages of development and rigorous testing protocols.
Acsia demonstrated its capability to manage balancer module projects within the BMS architecture. This involves the intricate task of balancing cell voltage within a battery pack, ensuring optimal performance and longevity of the battery. This skill is particularly relevant as the automotive industry continues to innovate and develop more advanced and efficient battery systems for electric vehicles.
Delivery Leader
Building a reliable power system for an autonomous vehicle demanded more than just engineering skill it required precision, adaptability, and close coordination across teams. From configuring the software stack to implementing key safety functions, our team approached each challenge with clarity and focus. This project was a reminder of how thoughtful engineering can make complex systems safer, smarter, and ready for the road.
SME
The project was a true showcase of Acsia’s ability to deliver high-complexity, safety-critical systems at scale. From decoding 800+ requirements to achieving ASPICE Level 2 certification on the first attempt, every milestone reflected our engineering discipline and customer focus. The successful integration of AUTOSAR, implementation of advanced diagnostics and cybersecurity, and 99% test automation weren’t just technical wins — they reinforced our position as a trusted technology partner for next-generation mobility platforms.
