Automotive industry Quality and Engineering

Veljko Massimo Plavsic
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This podcast is dedicated to Automotive Industry,innovation,research and development,quality and engineering and official vehicle recalls occured. If you want to share with me this passion for cars and engines you're in the right place and I would like to give you a warm welcome.

  1. Aug 6

    Digital Twins and impact on Quality Management (IATF 16949)

    Automotive Core Tools Integration APQP: The DT is utilized for filling/solidification simulations and topological optimization. While it enables virtual pre-validation, this does not replace physical validation required by PPAP unless explicitly agreed upon by the customer. FMEA: Failure modes must be expanded to include "Digital Failure Modes, such as model drift, loss of synchronization between the physical and digital twin, and training data corruption. MSA: Model outputs must be validated using metrics borrowed from Machine Learning, such as confusion matrices and sensitivity/specificity, alongside traditional accuracy and precision. SPC: Introduces hybrid SPC, where control charts monitor variables predicted by the DT in parallel with real-world variables, requiring capability studies (Cp/Cpk) on the model’s predictive ability. Regulatory Compliance: AI Act and ISO/IEC 42001 The EU AI Act (Reg. 2024/1689) follows a risk-based approach applied to specific AI functionalities within the DT. Classification:Minimal/Limited Risk: DT used only for offline engineering simulation without direct impact on product release or worker safety.Potentially High Risk: AI used as a safety component for products governed by harmonization regulations (e.g., Machinery Regulation 2023/1230) or affecting worker safety decisions.High Risk (Labor Context): DT used to monitor or evaluate operator performance.High-Risk Obligations: If classified as high risk, the organization must implement risk management systems, data governance to prevent bias, technical documentation, automatic logging of decisions, human oversight (the ability to override the DT), and cybersecurity measuresISO/IEC 42001 serves as the High-Level Structure (HLS) framework for governing the AI life cycle. Adopting this standard provides structured evidence of "AI Governance" often requested during second-party OEM audits.Cybersecurity and Information Security (TISAX & ISO/IEC 27001)The Digital Twin processes sensitive OEM technical data, including CAD geometries for structural castings and protected process parameters. This extends the scope of security requirements:TISAX / VDA ISA: The DT platform (local servers, MES storage, or third-party cloud) must be included in the assessment perimeter. A DT hosted on a third-party cloud or accessible remotely for maintenance may require Assessment Level 3 (AL3) with on-site audits.ISO/IEC 27001: The DT expands the IT/OT convergence surface. Key controls include:Organisational: Policies for AI/DT use and asset classification.Technological: Network segmentation (IT/OT), SCADA/MES vulnerability management, and encryption.

    Digital Twins and impact on Quality Management (IATF 16949)

  2. Aug 5

    Zeekr’s Innovation in Software-Defined Vehicle Engineering

    You can use my promo code AUTO25 to get discount on many great deals Follow my deals page on link below: https://mydeals.page/sc8t The transition toward Software-Defined Vehicles (SDVs) represents a fundamental shift in the automotive industry, where software serves as the central pillar of vehicle technology. Zeekr, a premium electric vehicle manufacturer, has implemented a sophisticated software factory approach to meet increasing consumer demands for intelligent cockpits and autonomous driving. Central to Zeekr’s strategy is the adoption of Model-Based Design and Service-Oriented Architecture (SOA), which allow for the decoupling of hardware and software development. By integrating traditional V-model rigor with Agile methodologies and DevOps practices, Zeekr has established a framework that ensures safety and functional reliability while enabling rapid software iterations. Key outcomes of this approach include a significant reduction in development cycles, lower costs through virtual vehicle simulation, and the ability to deliver continuous updates to consumers. Transition to Software-Defined Vehicles (SDV) and SOA As functional complexity increases due to intelligent technologies, Zeekr has moved away from traditional signal-based software toward a Service-Oriented Architecture (SOA). This shift is necessary to handle the interdisciplinarity and scale of modern automotive systems. Hardware-Software Decoupling: Zeekr prioritizes the complete decoupling of software from hardware, as well as the separation of internal software layers (operating system kernel, middleware, and application layer). This allows hardware and software to iterate at their own respective paces.SOA Benefits: Adopting SOA facilitates loose coupling between applications and hardware. This simplifies maintenance and creates an integrated ecosystem connecting on-board software, communication, security, and cloud environments.Custom Tooling (SOMOC): Zeekr developed SOMOC, a custom SOA software architecture maintenance tool. This tool was built using System Composer™, MATLAB®, and App Designer to manage the vehicle's custom operating system.

    Zeekr’s Innovation in Software-Defined Vehicle Engineering

  3. Aug 5

    Inside the Digital Twin: 5 Surprising Insights into How We Map EV Battery DNA

    You can use my promo code AUTO25 to get discount on many great deals Follow my deals page on link below: https://mydeals.page/sc8t Predicting the behavior of an electric vehicle (EV) battery is one of the most significant challenges in modern power electronics. For many drivers, the state of charge (SOC) indicator on the dashboard can feel like a best guess fluctuating based on how hard they accelerate or how cold the morning air is. This uncertainty exists because a battery is not a simple tank of fuel; it is a complex, dynamic chemical system that lives and breathes. To master this complexity, engineers perform Characterization. This is the rigorous process of extracting the electrochemical fingerprint of a physical cell ,such as the BAK N18650CL-29 lithium-ion cell,to create a high-fidelity Digital Twin. By mapping the underlying DNA of the battery, we can predict exactly how it will perform before it ever hits the road. Your Battery is a Different Creature at 0°C vs. 45°C A battery is a moving target. Its fundamental properties shift entirely based on its environment, making temperature the ultimate gatekeeper of performance. To build a robust digital model, characterization must be performed across a rigorous thermal spectrum. In the lab, we subject cells to Hybrid Pulse Power Characterization (HPPC) at five specific ambient breakpoints: 0, 10, 25, 35, and 45°C. At 0°C, internal resistance sky-rockets as ions struggle to move through the electrolyte; at 45°C, chemical reactions accelerate, potentially compromising the cell's lifespan. By mapping these thermal breakpoints, we ensure the vehicle’s software can accurately calculate range and power delivery whether the car is navigating a Norwegian winter or an Arizona heatwave. Short vs. Long Relaxation: Why Batteries Need Breathing Room When you stop drawing power, a battery's voltage doesn’t just snap back to a resting state; it relaxes over time. This relaxation is where the most valuable data is hidden, and it is measured using different rest periods to derive Resistor-Capacitor (RC) pairs. In our digital twin, a Resistor (R) represents the energy lost as heat (efficiency loss), while a Capacitor (C) represents the voltage lag or chemical memory of the cell.

    Inside the Digital Twin: 5 Surprising Insights into How We Map EV Battery DNA

  4. Aug 5

    Analysis of Battery State of Charge (SOC) Estimation Techniques

    You can use my promo code AUTO25 to get discount on many great deals Follow my deals page on link below: https://mydeals.page/sc8t Accurately determining the State of Charge (SOC) is a fundamental challenge in Battery Management Systems (BMS), particularly for electric vehicles (EVs) where it directly impacts range, safety, and battery longevity. Because a dedicated SOC sensor does not exist, the value must be estimated using physical parameters such as voltage, current, and temperature. The two primary methodologies for SOC estimation are Coulomb counting and the Kalman filter algorithm. While Coulomb counting is computationally simple, it is highly susceptible to errors in initial conditions and long term drift caused by battery selfdischarge. In contrast, the Kalman filter,specifically the Extended Kalman Filter (EKF)is a sophisticated estimation algorithm that infers the internal chemical state of the battery from noisy and incomplete measurements. Experimental data indicates that even when initialized with a significant error (e.g., an 80% estimate for a 50% actual SOC), the Kalman filter converges to the actual SOC in less than 10 minutes. Coulomb counting fails to correct such discrepancies. Consequently, while the Kalman filter requires greater computational resources and detailed system models, it remains the superior method for applications requiring high precision and adaptability to battery aging.

    Analysis of Battery State of Charge (SOC) Estimation Techniques

  5. Aug 5

    Guida ai Veicoli Definiti dal Software (SDV): Il Futuro dell’Automotive

    You can use my promo code AUTO25 to get discount on many great deals Follow my deals page on link below: https://mydeals.page/sc8t Che cos'è un Veicolo Definito dal Software (SDV)? Un SDV è un veicolo le cui caratteristiche, prestazioni e servizi sono abilitati e gestiti principalmente tramite software. In un approccio tradizionale, le funzionalità erano vincolate all'hardware: per migliorare i sistemi di assistenza alla guida o la gestione del motore, era spesso necessario sostituire componenti fisici. In un SDV, l'hardware è progettato per essere potente e versatile sin dall'inizio, permettendo al software di evolvere e aggiungere valore nel tempo. L'elemento di rottura fondamentale è la capacità di aggiungere funzionalità durante l'intero ciclo di vita del veicolo tramite aggiornamenti Over-The-Air. Per supportare un'evoluzione guidata dal software, l'architettura Elettrica/Elettronica (E/E) deve evolversi. In passato, le auto utilizzavano strutture monolitiche basate sui segnali, dove ogni centralina (ECU) parlava con l'altra tramite messaggi rigidi e specifici. Oggi, ci stiamo spostando verso architetture centralizzate e modulari. I tre pilastri di questa architettura moderna sono: HPC (High-Performance Computing): Vere piattaforme di elaborazione centrale che fungono da cervello del veicolo. Questi potenti computer ospitano le funzioni principali che un tempo erano sparse tra centinaia di piccoli controller.SOA (Service-Oriented Architecture): Un'architettura orientata ai servizi che rappresenta una vera rivoluzione rispetto al passato. Invece di programmi monolitici legati a segnali elettrici specifici, le funzioni software sono strutturate come servizi indipendenti. Questo permette al software di essere modulare, facilitando il riutilizzo tra diversi modelli di veicoli.Computer Zonali: Agiscono come local hubs situati in aree specifiche dell'auto. Il loro ruolo è gestire i sensori e gli attuatori periferici di una zona, aggregando i dati per inviarli all'HPC centrale. Questo approccio semplifica drasticamente il cablaggio e riduce il peso del veicolo.Sviluppare un SDV richiede processi industriali nuovi, mutuati dal mondo tech: nasce così la Software Factory. Qui il codice non viene solo scritto, ma gestito tramite flussi di lavoro automatizzati che garantiscono qualità e velocità.

    Guida ai Veicoli Definiti dal Software (SDV): Il Futuro dell’Automotive

  6. Aug 5

    Beyond the Engine: How Software is Rewriting the Rules of the Road

    You can use my promo code AUTO25 to get discount on many great deals Follow my deals page on link below: https://mydeals.page/sc8t The Identity Crisis of the Modern Automobile For over a century, the value of a car was a matter of metallurgy and thermodynamics the horsepower of its engine, the smoothness of its transmission, and the rigidity of its chassis. Today, that value proposition is undergoing a fundamental inversion. While many observers use the smartphone on wheels cliché to describe this shift, the reality for the industry is far more profound. We aren't just adding apps to a dashboard; we are witnessing a transition where the software now dictates the hardware’s value. As automotive complexity reaches an inflection point, the industry has embraced the Software-Defined Vehicle (SDV). This isn't a mere feature update; it is a structural solution to the limitations of mechanical hardware. In the SDV era, the driving experience, safety protocols, and even the vehicle’s fundamental performance are no longer fixed at the factory gate but are governed by the millions of lines of code running beneath the hood. Your Car is Never "Finished": The Power of Post-Purchase Updates In the traditional manufacturing model, a vehicle was a static asset. Once it left the assembly line, its capabilities were essentially frozen in time. The SDV lifecycle destroys this logic, moving the industry from a ship and forget mentality to a dynamic, evolving platform model. Software now defines vehicle functionality, creating consistent opportunities to add functionality during the life cycle" through frequent Over-the-Air (OTA) updates. This paradigm shift means the car you buy today can be objectively better, safer, and more capable two years from now. For the strategist, this represents a move from selling a product to managing a lifelong relationship with a digital asset.

    Beyond the Engine: How Software is Rewriting the Rules of the Road

  7. Jul 31

    Door Lock Microswitch Failure and Rollaway Risk in Mercedes-Benz VehiclesRoot Cause Analysis: Material Degradation and Environmental Factors

    You can use my promo code AUTO25 to get discount on many great deals Follow my deals page on link below: https://mydeals.page/sc8t Technical Overview and Incident Trajectory This report provides a strategic analysis of a significant safety recall initiated by Mercedes-Benz, affecting approximately 310,000 vehicles. In the context of modern integrated vehicle architectures, components formerly classified as "peripheral" or "convenience-oriented"—such as door lock assemblies—now function as primary sensors for the vehicle’s safety logic. The failure of these components represents a systemic liability, as it neutralizes automated safeguards designed to mitigate human error. The evolution of this issue underscores the danger of dismissing sensor irregularities as mere quality nuisances. For five years, the following trajectory was observed: 2021 – Initial Field Reports: Mercedes-Benz received the first set of consumer complaints regarding accessory power persistence (radios and interior lights remaining active after the ignition was terminated and the driver had exited).2021–2024 – Misdiagnosis as Quality Failure: During this period, the phenomenon was treated as a "comfort function" quality defect. Technical investigations focused on battery drain and owner annoyance rather than a compromise of primary safety systems.2024–2026 – Safety Reclassification: Following 176 field reports and a more rigorous technical audit, the failure was correctly reclassified. Engineers confirmed that the corruption of the door status signal not only affected accessory power but also suppressed the logic required to secure the vehicle’s transmission.July 2026 – Formal Recall: Mercedes-Benz filed documentation with the NHTSA identifying a widespread risk of vehicle rollaway due to electronic state blindness.This progression demonstrates how a hardware-level failure can effectively "blind" the vehicle's central logic, transitioning a minor electrical glitch into a high-consequence physical hazard.

    Door Lock Microswitch Failure and Rollaway Risk in Mercedes-Benz VehiclesRoot Cause Analysis: Material Degradation and Environmental Factors

  8. Jul 30

    How modern cars can become an entrapment: automatic door locking issue

    You can use my promo code AUTO25 to get discount on many great deals Follow my deals page on link below: https://mydeals.page/sc8t Vehicular heatstroke is one of the most persistent and devastating threats to child safety. While these tragedies are often discussed in the context of accidents, as a safety educator, I must be clear: these deaths are entirely preventable. The data from the National Highway Traffic Safety Administration (NHTSA) reveals a staggering loss of life that requires our immediate and sustained attention. The 25-Year Toll Over the last 25 years, more than 1,000 children have died from heatstroke because they were left unattended or became trapped inside a hot vehicle. This is not a historical problem that has been solved; rather, it is an escalating crisis. We saw record-breaking peaks in 2018 and 2019 with 53 deaths each year, and the tragedy continued into 2025 with 31 recorded fatalities. To end this cycle of loss, we must look beyond the statistics and confront the physiological reality of why a child’s body cannot survive the environment of a closed vehicle. Critical Insight: Do not underestimate the medical severity of these numbers. When a child reaches the 104°F threshold, their internal organs begin to struggle, and at 107°F, the body reaches a lethal state. This rapid climb can trigger irreversible brain damage or total organ failure in a matter of minutes. Because their bodies fail so much faster than an adult's, there is virtually no margin for error once the heating process begins. This biological vulnerability is exacerbated by the specific physics of a vehicle’s interior, which transforms a car into a high-efficiency heat trap

    How modern cars can become an entrapment: automatic door locking issue
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This podcast is dedicated to Automotive Industry,innovation,research and development,quality and engineering and official vehicle recalls occured. If you want to share with me this passion for cars and engines you're in the right place and I would like to give you a warm welcome.

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