Solutions for EMobility applications

EPowerlabs suports you throughout the process of component development for electric mobility applications, providing services at different stages of the process.

SKILLS AND CAPABILITIES FOR
E-MOBILITY APPLICATIONS

EPowerlabs offers end to end engineering services independently or supported by technological partners; from product requirements definition through the design of hardware and software, to the product validation.

INVERTER

DC/DC

E-DRIVE

xCU

BMS

ENGINEERING

  • Support in engineering projects at specific steps or within the whole development process (V)
  • Planning End to End projects autonomously or supporting our clients’ teams

Benchmark

  • Market and trend analysis
  • Technology benchmark and analysis
  • Powertrain system design and concept analysis
  • Manufacturer identification
  • Characterization of technologies
  • Comparative analysis of available technologies
  • Use cases analysis

Deliverable.

  • Market and technology analysis
  • Comparative analysis of products
  • List of suppliers / manufacturers
V_benchmark
V_definicion

REQUIREMENTS DEFINITION

  • Definition of system components
  • Definition of component functionalities
  • Definition of component specifications
  • System operating parameters
  • System integration mode (Master & Slaves)
  • Defining ports of entry and exit

Deliverable

  • Design project definition
  • Bill of Materials / Data Sheets
  • Testing and Validation Methodology

DEVELOPMENT

  • Inverter control design (0,5 kW – 300 kW)
  • BMS Hardware and Software Design
  • Design and prototyping of xCUs for High Performance solutions
  • Design of e-drives control software up to 30.000 rpm and (PMSynRM, PM, IM, etc) technologies
  • Developments with Infineon, NXP or Texas Instruments technology.
  • CAN communication and Autosar protocol development

Deliverable.

  • Hardware design (layout + materials)
  • Software Design
V_desarrollo
V_integracion

INTEGRATION

  • Integration of inverter with DC/DC converter
  • Redesign of the inverter control electronics
  • Software upgrade for electronic components
  • Redesign and adaptation of powertrains to operating curves
  • Inverter, Engine and Gearbox integration design
  • Systems integration for prototypes

Deliverable.

  • Hardware design (layout + materials)
  • Software Design

VALIDATION

  • Wide range of tests catalogue
  • Software in the Loop to improve design
  • Hardware in the Loop for calibration and testing
  • Validation of CAN communication
  • Definition of required EMC tests
  • Documentation and data sheet generation
  • Rout cause failure analysis

Deliverable.

  • Documentation / Data Sheets
  • Results analysis and evaluation report
V_disenio

TESTING

The testing phase is crucial step in a development project where the added value lies in several factors that have an impact on the total testing and validation period; such as the direct and fluid communication with the client, the effective testing time, and the integral testing process management.

The proper planning from the beginning is crucial to optimize the testing time and reduce the total costs. EPowerlabs offers its extensive experience in this field and focuses on designing testing programs to answer the key questions in testing processes:

  • What is the unit to be tested?
  • What is the purpose of the test?
  • How can it be tested?

METHODOLOGY DEFINITION

  • Test programme management and logistics
  • design and product validation program definition
  • Development of functional tests for inverters/e-drive/batteries
  • Support on durability and lifetime tests
  • Custom test catalogue definition for particular needs

TESTING SERVICES

  • Homologation cycles (R85) and (R100)
  • Characterization of electric motors. From prototyping to series production
  • Testing of automotive power electronics
  • Durability testing and life cycle estimation.
  • Thermal tests
  • Test automation under customer standards
  • Environmental Tests
  • Mechanical durability

ASSESMENT AND ANALYSIS

In multi-sample tests many data and case studies are generated, for which EPowerlabs offers the following services:

  • Evaluation of results and anomalies

  • Management and final reporting

  • Post Mortem Failure Analysis

  • Proposals for redesign and improvements

FUNCTIONAL SAFETY ISO26262

ISO 26262 is a standard published in 2011 as a response to the increasing complexity of electrical and electronic (E/E) systems and the risk this implies for the functional safety of a complete system. The ISO 26262 is recognized by the manufacturers and OEM’s of the automotive industry as the reference standard to minimize risks and ensure the competitiveness of the product in the market.

Examples of work packages we offer

  • Study and elaboration of the concept phase
  • Identification and definition of elements (Item definition)
  • Study of the safety lifecycle
  • Advice on risk analysis and assessment (HARA)
  • Safety analysis with techniques and tools such as FTA, FMEDA, FMDA
  • Definition of safety targets/goals
  • Development of the functional safety concept
  • Validation testing catalogue definition.
Development guideline based on EPowerlabs process