Engineering Capabilities
We deliver production-oriented engineering for EV on-board chargers — covering control software, power stage hardware, and mechanical integration from concept through bench-validated prototype.
Embedded Software & Control
Safety-aware control systems designed for deterministic real-time execution on Infineon AURIX platforms.
01. Control Strategy
Design of closed-loop voltage and current regulators (PI, PR) with simulation-first validation in MATLAB/Simulink. Includes plant modeling, stability analysis, and parameter tuning before deployment to hardware.
02. Code Generation
Custom, lightweight code generation pipelines producing deterministic, MISRA C:2012 compliant C code from Simulink models.
03. MCU Integration
Low-level driver development for AURIX TC3xx and TC4xx MCUs. Configuration of high-performance peripherals (GTM/eGTM, VADC, TMADC, DSADC) for precision PWM generation, synchronized ADC sampling, and real-time fault handling.
04. Communication & Diagnostics
Implementation of CAN, LIN, and SPI communication stacks for charger-to-vehicle integration. Support for ISO 15118 high-level communication concepts and on-board diagnostic (UDS) interfaces.
Power Electronics Hardware
Optimized converter topologies designed for high efficiency, wide-bandgap semiconductors, and automotive-grade reliability.
We specialize in isolated DC-DC converters — prominently Dual Active Bridge (DAB) — and active PFC front-end stages. Our designs target bidirectional operation (V2G-ready) and power densities aligned with OEM packaging constraints.
| Capability | Description |
|---|---|
| Topology Selection | Evaluation of DAB, LLC, CLLC, and PFC architectures for target power level and efficiency. Bidirectional (V2G) and unidirectional configurations. |
| Semiconductor Selection | SiC MOSFET and GaN HEMT dimensioning with loss analysis, thermal derating, and gate-driver design. |
| Magnetics Design | Transformer and inductor dimensioning (core selection, winding strategy, loss calculation) for high-frequency operation. |
| Schematic & PCB | Schematic capture in Altium Designer with EMC-conscious PCB layout, high-current path optimization, and creepage/clearance compliance. |
| EMC Pre-Compliance | Conducted and radiated emissions analysis, input filter design, and common-mode noise mitigation strategies. |
Mechanical & Thermal Integration
Physical realization of power systems meeting automotive environmental and safety requirements.
Thermal Management
Liquid and forced-air cooling system design with CFD-informed thermal simulations. Junction temperature analysis to maintain semiconductors within Safe Operating Area (SOA) across the full operating range.
Enclosure & Packaging
High-density packaging solutions for automotive environments. Vibration-resistant mounting, IP67 sealing, and connector integration for power and signal interfaces.
Prototyping & Test
Rapid physical prototyping and structured bench testing. Steady-state efficiency characterization, transient load-step response, thermal cycling validation, and waveform capture for control loop verification.
How We Work
A structured approach from initial concept through validated prototype.
01. Feasibility
Requirements analysis, topology trade-off, simulation-based feasibility assessment, and project scope definition.
02. Design & Build
Detailed design of control algorithms, power stage hardware, and mechanical integration. Iterative simulation and review cycles.
03. Validate & Deliver
Bench testing, waveform analysis, efficiency measurement, and thermal validation. Handover with full documentation and design data package.