ZoZo Auto Research has released the "2026 Zonal Architecture Series Research: Smart Actuators (Micro Motors) and Application Trends in Segmented Scenarios".ZCU
The core components of the automotive zonal architecture mainly include: the central computing unit, zone controllers, edge nodes (sensors and actuators), high-speed communication networks, power distribution modules, as well as software and network management systems.
Unlike the traditional split architecture of micro motor + gearbox + ECU, smart actuators integrate microprocessors, communication interfaces, drive circuits, and position feedback sensors directly with the motor actuation mechanism, becoming "smart terminals" equipped with local computing, status monitoring, fault diagnosis, communication interaction, action execution, and millisecond-level response capabilities. This significantly reduces the number of cable connections between traditional ECUs and motor actuation mechanisms, enabling intelligent and precise control of various vehicle functions. From a hardware composition perspective, smart actuators integrate edge sensing, local computing, communication, and driving into a single unit.
Edge Sensing: Automotive actuators themselves typically do not require sensors to directly drive their basic functions. However, within the overall control system of a vehicle, actuators and sensors work in close coordination, which is core to achieving "closed-loop control" in automotive electronics. Through "sensor feedback + actuator adjustment," sensors convert physical quantities into electrical signals and feed them back to the ECU. The ECU dynamically adjusts the control commands for the actuator by comparing the "target value" and the "actual value," thereby forming a closed-loop control.
Edge Computing: As the automotive EE architecture evolves from the traditional distributed and domain-centralized models to a "central computing + zonal control" architecture, local computing at the actuator level has become a key technological development direction. There are two main technical paths for local computing in actuators: remote-controlled edge nodes (actuators without an MCU) and smart edge nodes (motor control algorithms delegated to the actuator side).
Remote-controlled edge nodes: Through the RCP remote control protocol, the control logic of edge nodes (such as lights, doors and windows, sensors, etc.) is migrated from the local MCU to the central computing platform or zone controller. This allows the edge nodes to retain only basic I/O driving functions, becoming remotely accessible peripherals;
Smart edge nodes: This approach further delegates some computing tasks from the Zone Control Unit to the actuator end, which is closer to the physical action. A lightweight MCU or dedicated processing unit is retained at the edge node, and the actuator module includes an MCU, drive circuits, sensor interfaces, etc. This type of smart actuator possesses certain local data processing, decision-making, and control capabilities, independently completing real-time closed-loop control (such as motor PWM control, current monitoring, and anti-pinch algorithm execution) rather than relying entirely on commands from the central or zone controllers. Delegating motor control algorithms to edge-side actuators offers advantages such as faster instant response, sharing the computing power of the central computing platform/zone controller, and functional safety isolation;
Highly integrated motor drive SoC: The local computing capability of smart actuators relies on the advancement of underlying chip technologies, requiring highly integrated dedicated drive and control chips to provide power and control foundations for the actuator's local computing. Fully integrated embedded motor drive SoC products integrate functions such as MCU, power management (PMIC), CAN/LIN communication interfaces, gate drivers, and op-amps (operational amplifiers) into a single chip. Without the need for additional peripheral chips, they can complete the entire process of motor control, communication, and protection for smart actuators. Highly integrated motor drive SoCs are mainly used for controlling various actuators, thermal management pumps, and fans, providing underlying technical support for the mechatronic evolution of smart electric vehicles;
Edge Communication: Under domain controllers, various edge nodes have different application functions. Some non-real-time applications do not have high requirements for data transmission. Considering application needs and costs, traditional bus communication technologies such as CAN/CAN FD/FlexRay will continue to serve most low-speed communication networks in vehicles. However, under the zonal architecture, competition for 10M transmission rate applications will be fierce, mainly concentrated between 10Base-T1s and CAN-XL.
Edge Micro Motors: Micro motors are widely used in automotive body, smart cockpit, chassis, thermal management, and other fields. Examples include window regulators, seat adjustment motors, seat ventilation and massage systems, electric door drivers, in-vehicle display screen adjustment structures, automatic wipers, electronic pumps, electronic valves, and electric air vents. These end-point adjustment mechanisms achieve precise control of various vehicle parameters. Given the growth of intelligence in NEVs (New Energy Vehicles), the demand for micro motors will continue to grow with the addition of new functions and improvements in comfort. Micro motors are gradually evolving towards 48V motors, brushless motors, and mechatronics.
Zonal Control Architecture Spurs the Application of Smart Actuators
The development of the zonal control architecture will further promote the application of smart actuators. In the zonal control stage, the ZCU serves as the power distribution center, communication gateway, and I/O control center within the zone. It is connected to a central computer at the higher level and multiple actuators at the lower level. If all the underlying drive control of the actuators (such as micro-stepping control of stepper motors, commutation logic of brushless motors, position closed-loop feedback, etc.) is completed by the ZCU, it will consume a large amount of real-time computing power and increase the software complexity and code volume of the ZCU. From the perspective of simplifying wiring harnesses, since the ZCU still needs to directly drive a large number of motors, the wiring harness issue is merely shifted from the central level to the zonal level, not fundamentally resolved. This is uneconomical for a zonal control architecture that pursues efficiency and simplicity, and also contradicts its original intention of "simplifying software management."
Therefore, the new architecture requires delegating a large number of simple execution control functions to the "endpoints" close to the actuators. Edge nodes are required to have basic communication functions and certain local computing capabilities to implement single sensor signal processing or execution actions. This has spawned the demand for actuators with higher integration and local intelligence to simplify wiring harnesses, reduce costs, and improve system reliability. Smart actuators will become a perfect complement to the ZCU in the zonal control architecture. Furthermore, as the iteration speed of vehicle functions accelerates, under the zonal control architecture, adding new functions only requires adding smart actuators in the corresponding zone and connecting them to the existing network, without modifying the hardware architecture or extensive rewiring, thereby enhancing system flexibility and scalability.
Application Scenarios of Automotive Smart Actuators
Source: NXP
Smart actuators are widely used in fields such as body, chassis, thermal management, and powertrain, including electronic air vents, electronic water valves/expansion valves, hidden door handles, electric charging port covers, smart seat adjustments, AGS (Active Grille Shutters), in-vehicle rotating/lifting displays, AFS (Adaptive Front-lighting System) for adaptive headlights, electric power steering, brake actuators, and active suspensions.
Summary of Some Manufacturers and Product Solutions for Automotive Smart Actuators
Source: ZoZo Auto Research "2026 zonal architecture Series Research: Smart Actuators (Micro Motors) and Application Trends in Segmented Scenarios"
Taking Nidec's integrated EPS PP product as an example, this product integrates the ECU controller with the EPS motor, which can replace split motor control and provide auxiliary output for the vehicle's driving and steering system.
Bumpy roads: Nidec's EPS PP compensates for torque by identifying the torque fed back from the road surface to the sensor. This provides the driver with a steady feel and makes it easier to control the direction.
High-speed roads: Nidec's EPS PP collects vehicle speed signal information and provides a smaller steering torque at high speeds, making the steering more stable.
During parking or low-speed driving: After obtaining low-speed vehicle speed signal information, Nidec's EPS PP provides a larger steering torque, making steering smoother and facilitating parking or U-turns.
Nidec's Integrated EPS PP Product Integrates the EPS Motor and ECU
Source: Nidec
Under the 48V Low-Voltage Power Supply Architecture, High-Power Actuator Ends Prioritize Upgrading to 48V Motors
Transitioning from a 12V to a 48V automotive system has a significant impact on actuators. Traditional 12V motors, relays, and other components cannot be directly used in a 48V environment; their insulation levels and voltage resistance capabilities need to be redesigned. Additionally, the number of turns in 48V motors also needs adjustment. From the perspective of supply chain maturity, the maturity of actuators and load products such as 48V motors is relatively low, and their matching with PMICs (Power Management ICs) needs optimization.
Upgrading from a 12V power distribution architecture to a 48V power distribution architecture is mainly divided into two stages: the first stage is the coexistence of 12V and 48V electrical networks, and the second stage is a full 48V electrical network. Currently, it is in the stage where 12V and 48V electrical networks coexist, with a mix of 12V/48V loads within the controller zone.
Currently, not all actuators need to be upgraded to 48V, which is mainly based on power size and cost-benefit analysis. The load power must be at least 50W for 48V to show obvious advantages for 48V to show obvious advantages. Below 50W, the advantages of the 48V architecture are not significant. Therefore, in the upgrade to 48V motors, high-power loads with high power consumption are affected first. As costs gradually decrease and system benefits improve, the application proportion of 48V motors will continue to expand.
Applications of 48V Motors
Source: STMicroelectronics
Prioritize upgrading high-power loads: High-power loads (usually referring to 50W or 4A and above) are the priority for upgrading because they can significantly reduce wire diameter, reduce weight, and improve efficiency. For example, cooling fans are generally 350W, blowers are around 250W, water pumps are 120W, etc., as well as steering motors, active suspension motors, brake motors, and electric compressors. Many of these motors have very high power, making it highly necessary to switch to a 48V system.
Gradually convert medium-power 12V loads to 48V: For medium-power loads such as seat motors, wiper motors, and lighting systems, adopting a 48V system can increase the power output of the motors, thereby improving the driving stability and safety of the vehicle in harsh weather. Additionally, it can manage power demands more effectively and reduce system complexity.
Some low-power loads may remain at 12V: For some low-power loads, generally with a power of a few watts, the benefits of reducing wiring harness costs and improving efficiency by converting to 48V are not obvious. On the contrary, it increases costs significantly, and the cycle for reliability testing and verification such as salt spray, EMI, and ESD is greatly extended. Therefore, keeping some low-power loads at 12V and achieving drive through internal voltage conversion is actually simpler.
Some Segmented Application Types of 48V Motors
Source: ZoZo Auto Research "2026 zonal architecture Series Research: Smart Actuators (Micro Motors) and Application Trends in Segmented Scenarios"
Taking Johnson Electric's 48V electronic fan as an example, the cooling fan assembly module, through designs such as single-motor/dual-motor cooling fan assembly modules, forward-curved/backward-curved blade designs, and brushed/brushless motor solutions, can meet requirements for air volume, power demand, efficiency, weight, noise and vibration, and CO2 emissions.
Brushless motor platform: Full power coverage from 100W to 1500W, 12V and 48V; long life, high efficiency, reliability; lightweight; with/without PCBA;
Brushed motor platform: Power coverage from 80W to 500W; long life and reliability; optimal balance of weight, packaging, cost, and efficiency; stall protection;
Johnson Electric 48V Electronic Fan
Source: Johnson Electric
Taking Marelli's full active suspension electromechanical actuator solution as an example, the physical hardware of this solution consists of four electromechanical actuators. Each actuator is composed of a 48V brushless motor and a high-ratio reduction gear, connected to the suspension arm to actively move the suspension. The motor is controlled by a dedicated inverter, which receives stroke targets from the central unit hosting the vehicle dynamics software.
The system is powered by a 48V circuit integrated into the vehicle's electrical network, ensuring the correct energy flow. The central electronic control unit controls each actuator through electronic hardware and dedicated software. The software monitors various signals, such as acceleration, suspension stroke, steering angle, main propulsion unit parameters, brake pedal, torque demand, etc., and predicts the actions each actuator must apply to the suspension arm to set the appropriate reaction force. The drive unit integrated in the actuator receives the force demand from the central ECU and uses embedded algorithms to calculate parameters (target current) to drive the actuator's motor.
Marelli's Full Active Suspension Electromechanical Actuator Uses a 48V Brushless Motor
Source: Marelli
Brushless DC Motors Gradually Replace Brushed Motors, Becoming the First Choice for Automotive Motors in High-Performance Vehicles
A Brushless DC Motor (BLDC) is a type of DC motor that uses electronic commutation, achieving commutation through an electronic controller to replace traditional DC motors with carbon brushes. Because BLDC motors do not have brushes, their lifespan is much longer than that of brushed DC motors. At the same time, due to the absence of friction resistance from brushes, they have the advantages of higher conversion efficiency and low noise. Additionally, brushless motors can be paired with encoders to achieve more precise speed and position loop control. Due to their high efficiency, long lifespan, and low noise characteristics, BLDC motors have currently become the first choice for automotive motors. The addition of intelligent control algorithms makes motor operation more precise and smooth.
However, the internal structure of BLDC motors is relatively complex, and the drive circuits and algorithms are correspondingly more complex, so the cost is higher than that of brushed DC motors. They are currently mainly used in mid-to-high-end vehicle models that have high requirements for cockpit comfort, chassis, and thermal management performance.
Summary of Some Manufacturers and Product Solutions for Automotive Brushless Motor Layouts
Source: ZoZo Auto Research "2026 zonal architecture Series Research: Smart Actuators (Micro Motors) and Application Trends in Segmented Scenarios"
From the perspective of manufacturers laying out automotive brushless motors, mainstream domestic and foreign motor manufacturers all have a relatively complete layout of BLDC motor products. The applications involved cover body domain, chassis domain, and thermal management domain, such as EPS steering, SBW steering, EMB braking, air suspension, electronic water pumps, electronic oil pumps, electronic fans, wipers, and seats.
For example, the BL3040 internal rotor BLDC motor launched by Topband Motor is specially designed for the screen rotation system of NEVs. In addition to being used for in-vehicle ceiling screens, it can also be used for applications such as central control swing screens and central control lifting screens. This series of motors features an energy conversion rate of up to 75%, low cogging, high torque output, and low noise and vibration.
Topband Motor's Internal Rotor BLDC Motor Specially Designed for In-Vehicle Screen Motion Mechanisms
Source: Topband Motor
For example, the electric long slide rail for seats launched by Brose also uses Brose's self-developed brushless motor. Compared with ordinary motors, brushless motors ensure the stability of seat operation through motor control, bringing more sensitive precision; they can effectively eliminate the noise generated when brushes contact the rotor during the operation of traditional motors; and they bring application functions such as soft start/stop, anti-pinch, and easy entry to seat adjustment.
Brose's Electric Long Slide Rail for Seats Uses a Brushless Motor
Source: Brose
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