Worked integration: compact car

In one sentence Taken fully onto ASG, a mainstream compact car goes from 210 electrical nodes to 129, on a single ring served by 11 zone modules and 217 m of wiring.

The reference vehicle

The example is a compact family car from a segment that sells more than 100,000 units a year. The objective is a full transition: the whole electrical architecture moved onto the ASG control platform, not one domain at a time.

Every module serves the sensors and actuators in its zone over a two-wire communication bus and single-wire power, and all 11 modules commit one shared vehicle state every millisecond.

Before and after

Legacy ASG

electrical nodes †
wiring per vehicle †
zone modules †
connectors †

The point-to-point ECU set collapses onto one ring of zone modules. Toggle to replay. Numbers are for this worked compact-car integration.

Before After

Electrical nodes

210

129
Wiring per vehicle (m)

2,500

217

81 node functions are absorbed into the modules. The wiring “before” is the low end of the 2–3.5 km reference harness for a vehicle this size; the 217 m is measured for this configuration. See the methodology.

11

zone modules

350

connectors

~$450 †

wiring material

The 11 zone modules

M00 Master Z00

Nodes: 7
Load: 32%
Connectors: 44
Branch wiring: 22 m

Representative nodes

Vehicle-state master
Network gateway
Immobiliser
HV interlock monitor
Crash sensor
Diagnostic port
Redundant clock

Full reference

Module	Zone	Nodes	Load	Connectors	Branch wiring
M00 Master	Z00	7	32%	44	22
M01 Front right	Z01	11	31%	38	19
M02 Front left	Z02	11	31%	44	22
M03 Underbonnet	Z03	13	30%	46	23
M04 Control panel	Z04	8	30%	40	20
M05 Front right door	Z05	6	22%	32	16
M06 Rear right door	Z06	4	19%	18	9
M07 Interior, front	Z07	9	31%	24	12
M08 Rear interior	Z08	13	30%	14	7
M09 Front left door	Z09	6	22%	36	18
M10 Rear left door	Z10	4	19%	14	7
Total		92		350	175

Nodes shown are those each module directly controls. Load is the module’s utilisation. Branch wiring is the run from the module to its zone; the ring adds a further 42 m (see below). The plan view shows representative nodes; per-module counts, load and connectors are the compact-car figures.

Wiring composition

217 m total, power and data
Branch wiring to modules	175 m	Sum of the per-zone runs above
Ring communication	24 m	Two-wire, including connectors
Ring power	12 m	Single-wire distribution
Module-to-body	6 m
Total	217 m	Against a 2–3.5 km conventional harness

The result

One ring replaces the point-to-point electrical architecture and the buses that sat on top of it. Eleven universal modules replace the ECU set. The functions of 81 nodes move into module software, and what remains is wired on short branches to the nearest module.

For a platform selling six figures a year, that difference is multiplied by every vehicle built and by every year of the model cycle.

Questions

Is this a real vehicle?

It is a worked model of a mainstream compact family car, a segment selling over 100,000 units a year, re-architected fully onto ASG. The node inventory and the zoning are ASG’s.

How were the 11 modules placed?

By the proximity rule: the fewest modules such that every node is within its wire-length budget and no module is over capacity. The zonal ring architecture page explains the rule.

Does the 217 m include power?

Yes. 175 m of branch wiring to the modules, plus 24 m of ring communication, 12 m of ring power and 6 m of module-to-body cable.

What is the ~$450?

The wiring material cost for this configuration. The per-vehicle saving quoted elsewhere on the site is a broader bill-of-materials and labour figure; the methodology page separates the two.

Worked integration: a compact car on ASG