Energy Management and Power Distribution for Electrified Commercial Vehicle Architectures

FORVIA HELLA is integrating new energy management solutions, including the Intelligent Power Distribution Module and the EnergyCore concept, into the commercial vehicle segment. These technical systems are designed to support zonal architectures and the electrification of software-defined vehicle platforms.

Addressing the Industrial Challenge
Commercial vehicle manufacturers and transport fleets are experiencing an increasing need for fail-safe electrical architectures. If voltage drops or short circuits occur in conventional onboard networks, there is a risk that safety-critical systems such as steering, braking, or advanced driver assistance functions could fail. The shift toward software-defined vehicles therefore requires precise, maintenance-free power distribution units that isolate system faults early without destroying the physical integrity of the hardware. At the same time, installation space and weight restrictions force engineers to systematically minimize the use of materials in wiring harnesses.

Technical Architecture and Responsibilities
FORVIA HELLA’s Intelligent Power Distribution Module (iPDM) utilizes electronic fuses (eFuses) as the central switching component. These eFuses measure the power supply at high frequencies and control power distribution on demand in real time. Unlike conventional melting fuses, they operate reversibly and electronically interrupt the circuit as soon as defined limits are exceeded. In parallel, the EnergyCore concept bundles various components of power and battery electronics into a configurable hardware architecture as an X-in-1 system. The system supports voltage levels from low to high voltage and meets the requirements of functional safety up to ASIL D. Dr. Fabian Utermöhlen, Vice President Sales & Marketing of the Business Group Lifecycle Solutions at FORVIA HELLA, explained that the commercial vehicle market is moving toward zonal architectures, electrification, and software-defined vehicles, and that the energy management portfolio offers a scalable foundation for future vehicle generations.

Deployment and Operational Integration
Because of the maintenance-free eFuses, the iPDM no longer strictly needs to be installed in a freely accessible location in the cabin or chassis. This allows for flexible and decentralized placement within the vehicle structure. As a result, wiring harnesses can be designed with smaller wire cross-sections and shorter routing paths. The new systems are complemented by established components such as intelligent battery sensors for 12-volt and 24-volt onboard networks, as well as high-voltage DC/DC converters to ensure a stable 12-volt system voltage in electrified powertrains.

Applications and Use Cases
The system architecture is used in light and heavy commercial vehicles, electrified buses, and transport fleets. Within the system network, the iPDM ensures that safety-relevant actuators are continuously and redundantly supplied with energy, even in the event of faults in the onboard network. The EnergyCore architecture is applied for the integration of battery management and power conversion in future modular EV platforms.




Results and Operational Impact
By implementing the iPDM, the vehicle's fail-operational functionality is maintained, as faulty circuits are isolated before the entire system critically degrades. The reduction of cable lengths and material cross-sections in the wiring harness directly lowers the vehicle weight. These technical parameters lead to a measurable reduction in unplanned downtime and improve fleet efficiency. The technical solutions will be demonstrated at the IAA Transportation 2026 in Hanover, Germany (Hall 12, Booth 36).

Edited by Maria Brueva, Induportals editor – adapted by AI.

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