we keep you ahead components, via integration and validation to charger infrastructure.

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1 we keep you ahead electronics vehicle engineering solutions E-Drive CAx Methoden, Systems. Training & Support. We Ihr leistungsstarker support your development und zuverlässiger of the electrified Partner für future computerunterstützte by now from concepts, Prozesse. systems, and components, via integration and validation to charger infrastructure.

2 MBtech E-Drive Systems. Come drive with us into an emission-free future. Climate change, the debate over CO ² emissions, dwindling natural resources. All of them are topics and issues are more relevant now than ever before. Zero-emission driving long ago moved beyond being merely a subject for the trade press, and has now become a major area of focus for the public at large. Hardly a day goes by without an article on new drive concepts and storage technologies that supposedly or actually revolutionize the market. Amid all these rapid developments, it isn t always easy to keep an eye on the big picture. Our experts in the field of E-Drive Systems are able to do just that, however: Our advantage is that we have all of the relevant skills and expertise right here in-house, explains one senior member of the e-drive team, so we can support our partners throughout the development process from the very first idea to actual initial operation. One of our focal points is the development of e-drive components and systems. But we do even more. For instance, we also help test and validate entire concepts and business models, or we work with our partners to develop them. Expertise, experience, and flexibility. That s what our partners demand from us. They include OEMs and first-tier suppliers, but also all of the other players in the electric mobility sector. What s more, we have worked with this broad clientele for many years. We can look back on a large number of successful projects, and not just in the passenger car segment. That s also one reason we enjoy a great deal of trust and confidence. We do have to clear up one thing, though: There is no one-size-fits-all way to achieve zero-emission driving with electric drives. The path depends on your individual circumstances but we can help find the right one for you: for all drive variants purely electric drives, hybrid drives, and fuel cells. for all types of vehicles passenger cars, trucks, buses, and off-road vehicles. as a globally positioned organization in all regions at your location or ours. Our focus: electric drives P-HEV E-Drive FCEV BEV

3 Competences Idea Hybrid Fuel Cell E-Drive Series Consulting. We know the field from A (as in accuracy) to Z (as in zero emission). Efficiency and sustainability are the main principles that guide us as we develop alternative drives. And we don t mean just technologically far from it. What good is even the most efficient drive idea without the markets and customers to take advantage of it? What processes and structures are needed in order to make an idea cost-effective and feasible? We can help you answer these questions. Our experts can assist you with any aspect related to electric driving, from product strategy to strategic marketing considerations such as pinpointing your target customers, markets, budgets, processes, and structures. With our consultants, you can rest assured that you are always getting top advice, no matter what the circumstances. Full-service approach to alternative drive projects along the development activities Concept Development Systems & Components Integration & Validation Consulting & Project Management 2 3

4 Vehicle requirements Drivetrain concepts & operating strategy Simulation Optimal concept Check against general conditions System & component requirements Variants of implementation Concepts and vehicle properties. The optimum drive concept doesn t happen by chance. The range of possible drive options is wide, and keeping track of all of the variants is challenging. That s why it isn t such a simple matter to find the optimum concept for a planned application. Especially since we have to consider not only costs and fuel economy targets, but also aspects such as range, driving dynamics, and the availability of systems and components. Simulation is one suitable way to assess and compare different concepts and systems early on quickly and highly cost-effectively. At the same time, these simulations can help to identify the requirements that individual systems and components have to meet. This approach lets us find the optimum concept for any application, including yours. Concept evaluation DualX E-Drive Our Success Story Development and design of the DualX E-Drive electric drive concept for the MBtech REPORTER The MBtech REPORTER is a widely respected vehicle study from MBtech: a hybrid pickup with a drive concept designed by E-Drive Systems. With a simulation tool developed in-house, we were able to determine the necessary drive power and the size of the traction unit. Once we did so, it became clear that the only way we would be able to meet the many different requirements set by customers and the internal departments involved in the development process was by launching a new kind of drive concept: the DualX E-Drive a fully functional electric drive and a conventional combustion engine combined in a single overall system. Each part of the system drives one axle based on demand. The electric traction unit enables zeroemission driving for delivery vehicles traveling in the city. Over longer distances, the DualX E-Drive delivers extremely low driving emissions. There are also no significant restrictions in comparison to conventional vehicles. Plus, thanks to its innovative hybrid design, the DualX E-Drive achieves outstanding fuel economy values.

5 Requirements Simulation Concept Operating strategy Energy management From the initial idea to the start of series production concept development is an important building block in the entire development process. Creation of an alternative drive concept At the beginning, we use the vehicle specifications to determine and quantify the requirements that apply to the powertrain. We apply our experience and state-of-theart expertise at every stage of this process to help us identify early on where certain components require development. That saves time and money. During the project phases that follow, the vehicle is described in increasingly detailed models. This helps us visualize and validate the further development of the systems and components and optimize them where necessary. The development and validation of components are closely tied to this process. At the end, the given spec-book, the operating strategy, which has been optimized through simulations, and the energy management strategy together supply the basis for developing software for the actual vehicle. All of this means that you have the peace of mind of knowing you re on the right track at every stage of the development process Concept Development Requirements analysis Logic system architectures Technical system design 4 Functional model design 5 Simulation model design 6 Concept simulation 7 Concept evaluation E-Drive Simulation Doors Matlab Simulink CAD Tools 4 5

6 Component and system development. The heart of the electric powertrain is created. Development of components and systems starts early on, during the conceptual design phase for the overall system. During this stage, calculation and simulation data are compared against the feasible realworld specifications. Conceptual information is explored during the project and translated into technologically and economically viable solutions. This phase in the overall development of an electric vehicle is finalized with a combination of simulated and realworld validation processes that examine both individual components and subsystems. Nothing is left to chance. Our Success Story Foundation for a redesign: analysis and evaluation of existing e-drive engine concepts Core elements of an e-drive system Traction motor & transmission Standing still means falling behind especially in a dynamic industry like the automotive sector. That s why it is important to return to existing concepts and reexamine them again and again. When we start working on the redesign of an e-drive concept, we ask ourselves three questions: How can the concept be optimized, both technologically and economically? How can new ideas be shaped into a concept? What effects will changes have on the interfaces to everything surrounding the engine? For the answers, we turn to various actions. We analyze the engine manufacturing and assembly process along the entire production line. We break down the cost structure and evaluate it. We identify mechanical potential within the engine and design and engineer new mechanical parts. And we define and simulate an engine variant that has been optimized in terms of both technology and costs and adapt it to the existing specifications. This approach identifies and taps into the potential for purely economic optimization. Suggested changes to the mechanical design can also be made another kind of optimization. And above all, a result that gives the customer true added value. HV-battery system Power electronics Vehicle Control Unit Ancillary Unit

7 Power electronics Components E-Motor & Transmission Systems Review. We make sure everything is just right using proven methods and new approaches. Assuring the functionality and reliability of components is vitally important. That s why we adapt existing testing and validation methods on an ongoing basis, or develop new ones. Development and validation of e-drive systems and components 1 Specification and spec-book creation 2 High voltage safety and regulatory survey 3 Conception and simulation of components Doors 4 5 DMU and installation space verifications Functional simulation of selected components Simplorer/Maxwell Catia V4/V5 Matlab CANoe CANgraph 6 7 Verification of spec-book requirements by testing Planning and implementation of specific tests CANape Labview Diadem Tools Systems & Components 6 7

8 System integration. We bring it all together. Following component development, e-drive system integration is the next step toward achieving an electric vehicle suitable for the customer s needs. After the physical and electrical integration of all components and subsystems into a functional overall system at the vehicle level, follows the initial operation of components at the overall composite. Our expertise includes the following areas: Functional bus connection (CAN, LIN, MOST, FlexRay) System networking E-drive components and system know-how Evaluation of functions Measurement and testing technology Various types of trials and tests Data interpretation and analysis Standards and regulations Fault management Initial operation of components and systems High voltage know-how Our Success Story Initial operation of an e-drive system Challenge Integration of individual components into a functional e-drive system. Methods Mechanical integration 12-volt electrical cross-linking Application of tools for initial operation Initial operation of components Cross-linking of HV components Initial operation of overall system Validation of overall system Customer added value Operational e-drive system Adjustment of operating strategy to customer specifications Range optimization through defined operating modes (Sport, Eco)

9 System testing Vehicle networks Initial operation Validation Integration E-drive systems can be tested and proven in the vehicle or on test stands, but the vehicle level is more complex and cost-intensive. Integration and testing of all subsystems and overall systems in the vehicle An e-drive system has to meet many different requirements. Various functions, from those that ensure driver comfort and convenience to those that are critical for safety purposes, must be assured and the operating strategies must be checked based on the requirements. Once systems have been put into operation, we parameterize them to your requirements and adjust them as needed. The goal of our applications is to achieve maximum driving comfort and optimize the overall operating strategy. DTS (E-Tester) CANgraph INCA CANalyzer DIADEM LAB View Tools 1 System testing/system proving 2 Validation/Verification 3 Application/Calibration We offer you the component expertise necessary for initial operation of subsystems and overall systems along with proficiency in system cross-linking. Working with data analysis and diagnostic tools is part of our dayto-day business. 4 Initial operation Integration & Validation In future, we will configure our integration and validation services at next level. 8 9

10 Project management. We take the wheel for you. On demand, we care to take over the management of your project activities. In whole or in part, on-site at your location or right here in-house at MBtech. To accomplish this, we consider all of the project content involved in designing and creating an electric vehicle and break it down into individual work packages, clarify and work out responsibilities, and coordinate them afterwards. Depending on your requirements, we can provide you with project managers, subproject managers, or project support staff. All of our team members supply experience and knowledge, in both project management and in the specialized field of electric mobility. Overall project management for electric vehicles 1 Project leadership Planning and organization of complex projects 5 Planning and monitoring of timelines Control of development processes Quality assurance 6 Cost tracking

11 Work sample. Not every path takes you where you want to go. We find the right one that does. As we have already pointed out, there s no single right way to achieve zero-emission driving. Every single concept has to be developed individually a task we enjoy tackling. Our Success Story Determining the detailed flow of energy during the charging process for the traction battery of an e-drive vehicle Challenge To answer the following questions: How much charger energy actually reaches the battery? How large is the SOC hub used in the battery? How much of the energy supplied needs to be conducted thermally? How much energy do secondary consumers use during the charging process? Methods Conceptual design of the 12 V and HV measurement equipment Setup of measurement equipment and installation in the vehicle Implementation of 24-hour measurement of electricity, voltage, and temperature Application of high-voltage measurement tools (shunts) Identification of potential for optimization Charging process logging Charting activity and losses among the components involved Customer added value Technical solution: optimization of the charging process. Findings help achieve maximum efficiency during this process Built-in measurement equipment can also be used for further measurements, including during driving operations Documentation of results; in terms of digital data or thermal images 10 11

12 vehicle engineering power train solutions electronics solutions consulting Electrical & Electronics Architectures E-Drive Systems ECU Solutions Software Solutions XiL Test Operations EMC Services Tools & Equipment Electronics Consulting Europe MBtech Group GmbH & Co. KGaA Kolumbusstraße Sindelfingen Germany Tel Fax info@mbtech-group.com North America MB-technology NA LLC 400 E. Big Beaver Rd., Suite 300 Troy, MI USA Tel Fax info@mbtech-group-na.com Asia MB SIM Technology Co., Ltd. 6F Bldg. DOHO, No Wanhangdu Rd. Shanghai P.R. China Tel Fax info-mbsimtech@mbtech-group.com 03EDS-M201104G01-EN