System component sizing

  • Satisfying performance requirements (driving range, speed, acceleration, efficiency, etc)
  • Minimizing energy consumption
  • Maximize packaging efficiency
  • Powerplant system configuration examples for FCEV

  • Packaging variants with various H2 tank and batteries

  • Powerplant system (FC and Battery) power distribution strategies example


Vehicle conversion procedure

1. Packaging Design

  1. FC/PE system
  2. FC/PE Cooling system
  3. H2 supply system
  4. Wire harness
  5. HVCU
  6. Energy flow display
Packing design validates layout feasibility of vehicle components.

2. System Evaluation

  1. FC system
    - Performance
    - Efficiency
  2. HVCU control unit inspection test
  3. Battery/PE system
System level evaluation is executed to verify that each system satisfies the design specification.

3. Proto vehicle development

  1. Repainting
  2. Disassembly
  3. Components
  4. Filling hydrogen
After confirmation of systems, proto vehicle is built.

4. Proto vehicle test

  1. Calibration
    - Driving control
    - Power control
  2. Test
    - Fuel economy test
    - Drivability test
Vehicle level calibration is done and field test ensures the overall fulfillment of the vehicle development.

EV & FCEV platform development


Installation :
  • Fuel cell system (FC stack & BOP)
  • H2 tank
  • Boost DC-DC converter
  • Integrating junction box
  • FC radiator
  • etc

EV & FCEV platform development


Detachment :
  • Engine
  • Exhaust pipe
  • Fuel tank
Installation :
  • Battery
  • Motor
  • Fuel cell system (FC stack & BOP)
  • H2 tank
  • Boost DC-DC converter
  • Integrating junction box
  • etc

BEV Thermal management system

  • Define functions

  • System build and simulation

  • Rig test and validation


Hydrogen fuel supply system

  • System modeling

  • System strength simulation

  • Vehicle installation and test

Vehicle control unit development

Controller for system integration (VCU, HVCU, HMU, TMS, FCU)

  • Co-operative control (Traction control, regeneration, charging, TMS, …)
  • Function limit considering system components
  • Integrated E/E architecture
  • Fail-safe

xEV Benchmarking

Vehicle electric economy, driving performance, TMS and charging strategies analysis

  • Vehicle electric economy analysis

  • Thermal management system analysis

  • Charging control map analysis


Benchmarked vehicles list


  • BMW 330e PHEV
  • Audi A3 PHEV
  • Lexus UX250h HEV
  • KIA Sorento HEV


  • Tesla Model 3
  • Tesla Model Y
  • HMC Ioniq 5
  • KIA EV 6
  • Audi E-tron 55 quarttro
  • BMW i3
  • XiaoPeng P7 4WD
  • BYD tang 600D EV
  • BYD song pro EV
  • GM Bolt


  • Nexo FCEV
  • Elec-city FCEV bus
  • Benchmarking List (2019 ~ 2022)

Electric Component Test

E-PT, high-voltage battery and fuel cell system/BOP test is available

  • Motor test

  • E-PT test

  • EV battery pack teardown and component analysis

  • FC component test

  • FC system test

Analysis system for
mobile data loggers with web interface

For testing and optimizing their utility vehicles, most O.E.M operates a fleet of vehicles equipped with measurement systems. Several hundred signals related to the vehicle’s operation are recorded over an entire shift: temperatures, pressures, rotation speeds, brake pedal operations, accelerations and shifting operations as well as a large number of controller parameters. Several gigabyte of raw data is collected per vehicle and shift and automatically transmitted to a central server.


Pre – configuration for measurement

The main software configures vehicle state variables from control units and measurement devices to vehicle data logger. The results can be stored in itself or sent to web server.

Individual analysis for measurement data

For the analysis of measurement data, we can offer configurable analysis tool which can be easily adapted to the specific requirements without any programming work.

Overview in the web portal

All information and data for the test drives can be found in the company intranet via a clearly arranged web dashboard independent of time, location, and platform and can be used for analyses.
More Information