·       First product of its kind: intelligent Power Distribution Module (iPDM) ensures reliable and fail-operational power supply

·       Essential component of modern E/E architectures: Zone Controllers are another key product from FORVIA HELLA for complex control electronics

·       Less installation space, lower weight: as a first-to-market innovation,
electronic fuses (“eFuses”) are central components of iPDMs and Zone Controllers

·       Series orders: total volume of customer projects for iPDM and Zone Controller exceeds €1 billion

International automotive supplier FORVIA HELLA has launched its intelligent Power Distribution Module (iPDM) into series production for a premium manufacturer for the first time worldwide. As the first product of its kind, the iPDM ensures a reliable, fail-operational power supply in the vehicle and is thus a key component for highly automated driving. The iPDM is the first in the automotive sector to use so-called “eFuses” (electronic fuses).

“With over 25 years of experience and more than 13 million electronic control units manufactured annually, we are one of the world's leading suppliers of body electronics today,” says Jörg Weisgerber, Managing Director Electronics at FORVIA HELLA. “In the future, the development toward software-defined vehicles will fundamentally change the E/E architecture of vehicles. In order to consistently address this new future-oriented business field, we have significantly expanded our portfolio with iPDM and Zone Controllers, two new, forward-looking products for complex, intelligent control electronics, as well as eFuses as their key component.” 

iPDM and Zone Controllers are key products for modern E/E architectures

The intelligent Power Distribution Module from FORVIA HELLA continuously monitors the power supply in the vehicle using built-in eFuses and the corresponding software. Potential failure risks, such as cable overheating, can thus be identified and rectified before they become critical. The basic functionality of safety-related driving functions in particular, such as driver assistance, steering, and braking systems, can thus be maintained at all times (fail operational).

While iPDMs primarily secure the power supply, Zone Controllers – FORVIA HELLA's second key product in the field of intelligent, complex control units – have a much wider range of applications with regard to the collection, processing, and forwarding of data. In a connected network within the E/E architecture, Zone Controllers ensure that the electrical consumers in the respective vehicle zone receive the necessary energy and protect them from overload. Zone Controllers also collect data from sensors in the vehicle in real time, process it, and use it to control actuators for windows, lighting functions, or windshield wipers, for example.

A first in the automotive sector: eFuses as a central component in iPDM and Zone Controllers

In the functioning of both the iPDM, which has now been launched, and of Zone Controllers, which will go into series production for another well-known automotive manufacturer in mid-2028, eFuses are key components. While conventional fuses melt and become unusable in the event of a defect, eFuses are completely maintenance-free due to their reversible functionality. This means they do not need to be installed in the vehicle in a freely accessible location. As a result, the weight of the wiring harness can be reduced by up to 25 percent thanks to increased flexibility in the installation space and more precise fuses.

FORVIA HELLA has consistently further developed its eFuses for Zone Controllers and future iPDM product generations. With its highly integrated iConF product solution, FORVIA HELLA is the first automotive supplier worldwide to combine an eFuse with a specially designed ASIC chip and intelligent control software. This further reduces the installation space, lowers component requirements, and enables intelligent data acquisition and processing.

iPDM and Zone Controllers are developed at FORVIA HELLA's headquarters in Lippstadt (Germany) and at the Technical Centers in Craiova (Romania) and Pune (India). The total order volume of these series projects for iPDM and Zone Controllers exceeds €1 billion. Series production takes place at the electronics plant in Timisoara (Romania).