Electro-Thermal Model-Based Design of a Smart Latch in Automotive Systems for Performance and Reliability Evaluations

Industry 5.0 places growing emphasis on intelligent and efficient design methodologies aiming to reduce development times, accelerate the time-to-market, and enhance human–machine collaboration in creating new products. This article proposes the use of a model-based design (MBD) approach to developing a detailed electro-thermal model (ETDM) of a Smart Latch Mechanism (SLM) used in automotive door automation systems. The proposed ETDM enhances the accuracy of the design and verification processes and enables the simulation of specific scenarios, such as fault conditions, within a virtual environment. The simulation-based framework presented in this article leverages partial knowledge of the system to enable rapid estimations of the performance and functional validation. It encompasses the injection of disturbances, the analysis of failure scenarios, and the use of processor-in-the-loop (PIL) procedures for validation purposes. This work aims to employ detailed modeling and simulation techniques and use publicly available technical data and work from the literature to eliminate the need for physical testing and instrumentation, enabling the development of models that accurately reflect the real-world behavior under defined operating conditions. The proposed framework has the potential to facilitate rapid prototyping and system reconfiguration, contributing to shorter development cycles and improved industrial efficiency by reducing both production times and the associated costs for established automotive subsystems where high precision is nonessential.