Electric Vehicle (EV) was once thought of as a futuristic concept. Today, it has become a reality. It’s at the forefront of a global automotive revolution. However, the revolution path is fraught with unprecedented challenges.
There is constant pressure on EV Original Equipment Manufacturers (OEMs) and startups to shorten development cycles. Simultaneously, they are also driven to adhere to emission-critical safety norms. This is where PLM (Product Lifecycle Management) comes into play. Companies can by harnessing the immense capabilities of an integrated PLM Software suite, manage the whole of the digital thread, from the first sketch to the final assembly line.
HOW TO ACCELERATE EV INNOVATIONS WITH INTEGRATED PLM?
Here’s how to accelerate EV innovations with integrated PLM.
STAGE 1: BRIDGING THE GAP BETWEEN CONCEPT & REALITY
Speed in the early stages of EV development is everything. Fast-paced innovation however often leads to ‘data silos.’ Mechanical team, battery engineers, and software developers all work together on different versions of the same product.
THE SINGLE SOURCE OF TRUTH
PLM Software functions as a centralized digital repository. It ensures every stakeholder is looking at the latest data. Be it in the R&D lab or the Procurement Office. This ‘Single Source of Truth’ eliminates the risk of expensive late-stage design changes that happens when hardware and software are out of sync.
KEY CONCEPTUAL BENEFITS
- REQUIREMENTS MANAGEMENT: Link directly high-level goals (like a 400-mile range of 5-star safety rating) to specific engineering components.
- MULTI-DISCIPLINARY DESIGN: Integrate into a single unified setting mechanical CAD (MCAD), Electrical CAD (ECAD), and Software Code.
- SIMULATION-DRIVEN DESIGN: Test virtually the thermal behavior of a battery pack or the aerodynamics of a chassis. This helps reduce the need for physical prototypes.
STAGE 2: MANAGING THE COMPLEXITY OF THE ‘SMART’ VEHICLE
The transition to EVs has altered the value of a vehicle. It has graduated from mechanical engine to electronic architecture. Modern EVs require advanced Battery Management Systems (BMS) and Advanced Driver-Assistance Systems (ADAS).
SOFTWARE AND ELECTRONICS INTEGRATION
Software is treated by traditional manufacturing processes often as an afterthought. Integrated PLM allows for Application Lifecycle Management (ALH) integration. The software controlling regenerative braking is developed, tested, and versioned alongside the brake pads.
WHY INTEGRATED PLM IS VITAL FOR EV ELECTRONICS?
- BOM MANAGEMENT: Complex Bill of Materials (BOM) account for thousands of electronic sensors and high-voltage cables.
- CONFIGURATION CONTROL: Manages different vehicle variants. Like for instance, standard range VS long range, without creating data chaos.
- REGULATORY TRACEABILITY: Automatically documents every character. This ensures compliance with global safety norms like ISO 20262.
STAGE 3: REALIZING PRODUCTION EFFICIENCY
Moving from a prototype to mass production is often in the EV world called ‘Production Hell.’ PLM Services help bridge the ‘Valley of Death’ between design and the shop floor.
THE DIGITAL TWIN OF PRODUCTION
Engineers can by creating a digital twin of the factory itself, simulate the entire assembly process before a single piece of equipment is installed.
They
- Allow ‘Virtual Commissioning.’ This involves testing in a virtual world the robotics and PLC (Programmable Logic Controller) code.
- Ensure the assembly line runs smoothly on day one.
STAGE 4: SCALING WITH EXPERT PLM SERVICES
Many EV startups aim to be agile and lean. This is where PLM services-including consulting, cloud migration, and system integration- are essential.
RISE OF CLOUD-BASED PLM
Companies can with cloud native PLM Software scale their infrastructure as they grow. Additionally, they can also use a Software-as-a-Service (SaaS) model instead of investing in massive-on-premise servers. A startup with ten or more engineers will have access to the same high-end tools as a global automotive giant.
PLM SERVICES
- SYSTEM INTEGRATION: Connects PLM to ERP and MES.
- DATA INTEGRATION: Moves legacy design data into a modern, searchable environment.
- WORKFLOW OPTIMIZATION: Designs automated approval cycles that speed up ‘Engineering Change Orders (ECOs).
STAGE 5: SUSTAINABILITY AND THE CIRCULAR ECONOMY
Finally, sustainability like for all industries is the mission of the EV industry. PLM helps manufacturers to track their vehicles’ environmental impact throughout their entire lifecycle.
- MATERIAL TRACEABILITY: Tracks the sourcing of rare minerals like Cobalt and Lithium.
- BATTERY SECOND-LIFE: Manages data on battery health. This facilitates ‘second life’ uses in stationary energy storage.
- RECYCLING MANAGEMENT: Provides ‘end-of-life’ instructions. They ensure vehicle components are responsibly disposed of or recycled.
CONCLUSION
Future transportation will primarily be driven by data. Manufacturers to win the EV race will need to move faster and collaborate better. They will also need to eliminate waste safely. Integrated PLM offers the digital backbone required to convert a visionary concept into a high-performance production vehicle. EV companies can by investing in the right PLM Software and leveraging professional PLM services of CJ Tech, focus on innovating for a cleaner, smarter world.
FAQs
1. Can PLM manage millions of code lines in modern EVs?
Yes. Modern EVs are ‘Software-Defined Vehicles.’
Integrated PLM
- Allows for ALM (Application Lifecycle Management) integration.
- Ensures that a software update to the regenerative braking system is synchronized perfectly from the hardware’s specification of the motor. This prevents ‘version mismatch’ errors that could lead to recalls.
2. How is production accelerated by a ‘Digital Twin’ in PLM?
A Digital Twin indicates a virtual mirror of the physical vehicle and the factory. Engineers can by using PLM Software ‘virtually commission’ the assembly line. They can test in a virtual world the robotics and assembly sequences before the factory is even built.
This will help
- Identify early the bottlenecks and safety issues.
- Reduce the time to ramp up full production by months.
3. Is sustainability supported by PLM? Does it also support ‘Circular Economy’ goals?
Yes. Tracking materials from start to finish is among PLM’s unique roles in the EV sector.
- COMPLIANCE: Ensure sourcing of minerals in an ethical manner.
- RECYCLING: Provides auto-dismantlers with exact material lists and safety instructions. They ensure safe battery disposal at the end of the vehicle’s life.
