Solutions

40+ Patents resulting from Createering team.

 

Electrical Design
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  • Full SW and HW capability
  • Component, PCB, sub system and system level including interface communication and control
  • Complete design from layout to prototypes to debugging and finalization
  • Cable and harness specifications and drawings
  • Conversion of PLDs to ASICs
  • Battery management system (BMS) development
  • Battery pack design for specific applications, traction power for EV drive train
  • Multiple chemistries – NiMH, SLA, LiFePO4, LiMnO2 (cylindrical & prismatic configurations)
  • Motor controller, electronic commutation, battery charger, interface control module
  • Power and CANbus distribution
  • Instrumentation and lighting design and control
  • PC based diagnostics via CANbus
  • Regenerative energy applications
  • Frame grabber, image processing, and data acquisition system design
  • Memory management utilizing VRAM, DRAM, SRAM, FIFO
  • PLC Programming using PLC Direct, Allen Bradley, and Modicon
  • Design and testing systems for:
    • Single and 3 phase motors
    • Single and 3 phase brushless DC motors
    • Transformers
    • Variable frequency drives (VFD) and power circuits

Tools: OrCAD Capture and Layout, ViewLogic, Altera, Microchip IDE, C and Assembly, Pro/Engineer, Solid Works, AutoCAD R14, Microstation, MATLAB, Data acquisition equipment (HBM, Agilent, HP, LabVIEW)
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Mechanical/Structures Design
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  • Full structural design and analysis capabilities
  • Design and analysis of primary and secondary structures linear, non-linear, and buckling finite element analyses frame, suspension, wheel, gearbox structures
  • Composite structures
  • Vehicle design
  • Chassis geometry and layout
  • Frame design wheel and tire sizes, wheelbase, rake and trail dimensions, swingarm length and geometry, rear shock leverage ratio, front and rear suspension travel
  • Loads development for chassis testing
  • Static, dynamic, and fatigue
  • Drive train
  • Gearbox
  • In-wheel integrated transmission
  • Surface and tooling design
  • Molds, castings, body panel tooling
  • Develop mechanical manufacturing and incoming inspection fixtures
  • Battery pack packaging, interconnect and cooling
  • CAD/CAM

Tools: PATRAN, MSC/NASTRAN, SDRC I-DEAS, PANDA, CADAM, AutoCAD, SolidWorks, CosmosWorks, ANSYS, Pro/Engineer
System Integration and Test
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  • Battery pack:
    • High peak power (<20kW) and energy (<5.4 kWh) battery systems for EV
    • Failure modes
    • Charging requirements
    • Discharging requirements
    • Multiple chemistries - NiMH, SLA, LiFePO4, LiMnO2
    • Battery cooling and air flow requirements
    • Charge and discharge knowledge and their associated Motor Controller (MC) & charger associated algorithm
  • Electromagnetic Compatibility (EMC) test and evaluation – component and system levelCreation and execution of test procedures and acceptance criteria
  • SAE, FMVSS, CMVSS, EU ground vehicle requirements
  • Dynamometer ground vehicle characterization
  • Range, top speed, acceleration, trip profiles
  • Durability test mechanical and electrical
  • 3rd party testing
  • Environmental, EMC, product certification
  • Manage government, regulatory, industry compliance/certification and vehicle homologation
    UL, IEC, CE, FMVSS, CMVSS, CCC, DOTAR, …
  • Conformance of Production (CoP)
  • Failure Modes and Effects (FMEA) analysis
  • Conduct, document and analyze environmental, operational and performance tests at the system and sub-assembly level
  • Environmental testing, HALT/HASS
  • Manual and automated test, and analysis of electronic circuitry and systems
  • Mechanical assemblies and systems
  • Control system and Human Machine Interface(HMI) Software development
Quality Management Systems (QMS) and Continuous Improvement
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  • Full knowledge and experience of industry QMS
  • ISO 9001
  • ISO/TS 16949
  • ISO 14001/18001
  • Six sigma based improvement methodology
  • Failure analysis, root cause determination and corrective action
  • Process development, monitoring, and optimization
  • NPD verification/validation, design review, transition to production
  • Process, product, and system audit
  • Incoming, in-line, and final product verification
  • Global supplier development and improvement
Manufacturing Operations
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  • Full knowledge and experience in mechanical, electrical, electro-mechanical assembly
  • Production line design, layout, and set up
  • Automation
  • Process flow
  • Rated throughput
  • Facilities management
  • Process development
  • In-line monitoring and test
  • Supplier development
  • Piece part specification and procurement