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Electronics development – prototype and serial production

Simulation for optimum results

In our simulation area, we test concepts even before they reach the technical implementation stage, thus speeding up the development process and reducing outlay for mechanical measurements. We use suitable tools such as Matlab / Simulink to ensure that our simulations are realistic.

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System simulation

  • Execution of system simulations, system studies and overall system simulations
  • Model-based function development according to the V-model
  • Simulation of the system conduct of complex processes and modelling of strongly networked systems
  • Time-range analyses (transient simulations)
  • Development of customer-specific models and model expansions
  • Solving general control-technical tasks
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Drive simulation

  • Concept comparison and optimisation of drive systems
  • Application-specific optimisation of drive systems regarding the interaction between motor, electronics, and control strategy
  • Simulation of drive and power electronics, motor and control in various model depths / detailing
  • Development and optimisation of control strategies for EC-drives (power loss optimisation, efficiency, and robustness increase, noise optimisation and optimisation of the overall system conduct)
  • Execution of threshold and worst-case simulations
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Controller development & design

  • Draft of digital control concepts (MIL-, SIL-, and HIL-simulation)
  • Development of robust control algorithms for EC-drives
  • Regulator design of “low-cost” drive systems
  • Design and concept comparison of sensor-free drive and control procedures
  • Rapid control prototyping – use of real-time development systems
  • Controller design and parameterisation by offline simulation (MIL) and online simulation (HIL)
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Circuit & power loss simulation

  • Performance of analogue and digital circuit simulations
  • Power calculation of end stages and inverter systems
  • Detailed simulation of power loss in power end stages / semi-conductors (MOSFETs, IGBTs)
  • Simulation of input filters, noise suppression components, and protective circuits
  • Simulation of hardware circuit modules
  • Component dimensioning of circuit assemblies and individual components
  • Consideration of producer-specific components by import of SPICE models is possible
  • Execution of thresholds and worst-case simulations
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Thermal simulation

  • Thermal 3D-FEM-calculations
  • Execution of static and dynamic simulations
  • Simulation of the thermal cooling concept of assemblies and components
  • Determination of the specific thermal resistance of components in the overall system (Rth- / Zth-resistance)
  • Execution of threshold and worst-case simulations
  • Generation of thermal replacement models for direct coupling with the system simulation
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E-motor design / calculation

  • Setup and design of electric motors (EC-, DC-, synchronous machines)
  • Geometric design of the magnetic circuit of rotor and stator
  • Construction of sheet cuts
  • Design for high temperatures
  • Analytic calculation and simulation by FEM