(EV) Electric and (HEV) Hybrid Vehicles
From NewEagleWiki
Capability Overview
The need for a rapid transition towards electrification in today’s transportation industry is clear, but the experience and knowledge required to transform these new ideas to reality are scarce. New Eagle continues to grow its hybrid and electric vehicles team. Our expertise lies in the integration of the vehicle electronics, energy-storage and powertrain controls. We can help you create, integrate as well as execute your plan! New Eagle’s engineering team has experience helping its clients move from initial concept to prototype to production working as either consultants or integral developers of the system.
Supply Chain Partner (EV Bill of Materials)
New Eagle uniquely has a full set of components available for the design and manufacture of electric vehicles. We provide access to our suppliers via our engineering and distribution combination.
For a full EV/HEV bill of materials available from New Eagle including:
- EV Powertrain (Motors, Inverters, Gearbox)
- DC/DC
- High Voltage Charger
- Vehicle Controllers (Supervisor)
- CAN Gateway
- Displays
- Battery System
- Battery Accessories
- Brake/Steering
- HVAC System
- Service and Diagnostics Tools
Contact Sales for a copy of the products available. Also, we have a full EV drivetrain for retrofit or small volume OEM passenger cars.
Application Experience
Relative to the experience of Hybrid / Electric Vehicles, we bring application experience in:
- Advisor for Design / Technology
- Electrical System Architecture
- Experience in parallel, series and power split hybrid system
- Advisor for Design / Technology
- Systems Engineering
- Powertrain
- Chassis
- Body
- HVAC
- Systems Engineering
- Drivetrain
- Electric Motor
- Inverter
- Transmission
- Drivetrain
- Energy Storage Systems
- Battery, Ultra-capacitors, Chargers
- Energy Storage Systems
- Controls and Software Development
- EV Supervisory Control
- Controls and Software Development
- Energy Optimization
- Fuel economy / range simulation
- Engine control – Range Extenders
- Energy Optimization
- Vehicle and Component Validation
- Low and High Voltage Wiring Design
Electric Vehicle Supervisor
New Eagle offers EV integration and can supply controls through every stage of development, from concept to production. Using its network of component suppliers and years of experience developing electric vehicle control algorithms, New Eagle has developed different levels of the Electric Vehicle Supervisor offering to cover a wide variety of applications shown below. These products and services levels are:
- EV System Architecture Design Service
- EV Supervisor Start-Up Kit
- Turn-key EV Control Module (EVCM)
- EV Supervisor Custom Solution
1) EV System Architecture Design Service
New Eagle has significant experience in the creation of EV system architecture concepts and designs, particularly in regards to the system controls network. In some cases, this may be developed by the customer prior to engaging New Eagle. In the case that the customer has either not developed or needs to modify the system architecture or controls network, New Eagle can assist by conceptualizing the necessary layout. The conceptualization utilizes an experienced New Eagle engineer and typically takes a week with deliverables of a concept diagram, description documentation and implementation strategy.
For information on help developing an EV System Architecture, Contact Sales
2) EV Supervisor Start-Up Kit
The New Eagle Base EV Supervisor Kit is a recommended set of software and hardware components that are recommended for rapid electric vehicle development. It starts with the MotoHawk reference model for EV Supervisory or Vehicle Control.
The MotoHawk EV Supervisor model is source code with templates intended to help a user get the project started and save time to finish the application. This software has been verified and field tested across multiple applications, and can be used by the vehicle integrator as a base platform for developing a unique EV vehicle application.
Please go to the store for more information. Webstore: EV Supervisor Template
The available hardware from New Eagle begins with a dual channel pedal, pig-tail harnessing, a controller, a color display, and the MotoHawk software template to build a custom control system. Training and support is also available from New Eagle.
3) Turn-key EV Control Module (EVCM)
If you are a customer who wants a pre-programmed controller, with little tooling or development costs, the New Eagle turn-key Supervisory offering is for you. It includes a fully pre-programmed control module that connects to driver inputs and sends a torque request to an inverter/motor system. With this system, the electric vehicle developer will be able to rapidly integrate EV system components. Support and training is also available.
Hardware:
New Eagle put together this kit with driver and vehicle inputs, outputs, and a display interface to jump start your integration of inverter/motor and other EV system components.
Software:
The module and display come pre-programmed and ready for integration. This software can be calibrated to your vehicle specifications using MotoTune.
For information on our turn-key EV Supervisor to build your own Electrical Vehicle, More Information on EV Supervisor Start-Up kit
4) EV Supervisor Custom Solution
In many cases, our customers have unique requirements that require a custom solution for the EV supervisor.
This image depicts a typical supervisory control architecture for production EVs. For custom solutions, New Eagle develops controls solutions for a broad range of applications utilizing production validated electronic control units and the MotoHawk® model based code generation platform. A main focus for New Eagle is the EV and HEV market. New Eagle customers benefit from the field tested hardware and software solutions that are provided while tailoring the application to their particular niche. New Eagle is efficient at reuse of hardware and software while keeping customer specific applications confidential and protected. No time is wasted developing non-differentiating solutions as New Eagle is able to focus on the critical product parameters, thus saving significant overall non-recurring engineering costs by as much as 80%.
As part of New Eagle’s dedication to lean product development and reuse, New Eagle has designed an EV product development framework. This framework allows New Eagle to quickly work with customers to create and manage a product development plan to their needs. New Eagle uses the Talon Product Development Process to take programs from proof of concept through product launch and then to production. Development phases are divided into concept validation (CV), design validation (DV), product validation (PV) and series production phases. A copy of the product development framework can be found in the appendix.
New Eagle has recognized the need for customer compliance to the evolving safety standards of the automotive industry. As such, New Eagle has developed tools to guide the development of robust software functions for adherence to ISO26262 standards.
Please contact us to work with our EV-HEV team to develop or support your program.
Additional EV Supervisor Information
EV Supervisor Brochure
The complete EV Supervisor offerings are described above are written with greater detail in the EV Supervisor Brochure
Torque Security Strategy in the EV Supervisor
New Eagle recommends a multi layered diagnostics and fault management approach on torque security for the EV supervisory controller, the VCU (Vehicle Control Unit). The following basic strategy was developed by the VDA (Verband der Automobilindustrie), the German Automobile Industry Association for egas (electronic throttle) equipped vehicles:
The basics of the 3 level strategy:
Level 1: Assume that your software and controller hardware are working correctly. Diagnose the sensors, actuators, etc. via electrical checks and rationalities with redundant sensors. A lot of this demands a design philosophy which eliminates single path failures leading to the same error on redundant paths (e.g. sensor power supplies).
Level 2: Assume that your controller hardware is working correctly. Diagnose software with RAM and ROM checks and “software rationalities” via redundant code running in parallel to validate the calculations and commanded actuator positions.
Level 3: Assume that nothing is working correctly (microprocessor is suspect). Second “safety” micro is utilized with the ability to interrogate and reset the main micro, and ability to cut power to the fuel injectors (or some other actuator critical to operation). Questions are sent from the main micro to the safety micro and through a carefully constructed scheme, each micro can tell if the other is faulty.
Interfaces Available
This list is not complete, but indicative of our ability to adapt the product.
- EV Inverters
- Semikron
- UQM
- RMS PM Family
- Azure DMOC
- Parker SSD
- Pedal Interfaces
- Kongsburg
- Orscheln
- Battery Management Systems
- eLithion
- Dow Kokam
- Lithium Balance
- New Eagle Custom or Proprietary
Battery Management System
New Eagle is pleased to offer a complete BMS solution with robust hardware and software designed to fulfill all of the necessary BMS functions. This offering is expandable from 12 to 180 cells in series for a wide variety of cell chemistry and pack configurations and includes pre-wired harnesses. Some of the many BMS features are listed below. In addition, New Eagle offers a config file for the BMS that allows for an off the shelf working solution with the EV Supervisor kit.
- Fully Configurable PC Interface (shown above)
- State of charge calculations
- Cell over-voltage and under-voltage protection
- Current sensing (bi-directional)
- Current limits (charge and discharge)
- Isolation Detection and Monitoring
- Intelligent battery balancing (passive)
- Centralized design provides high EMI and noise immunity.
- Battery charger control
- Pack temperature monitoring
- Monitors health of battery pack
- Configurable CAN communication
- Open cell voltage calculation
- Busbar resistance compensation
New Eagle and its partners have extensive experience building battery packs for a variety of applications.
Please contact us to work with our EV-HEV team to order a BMS for your battery application.
Electric Drivetrain
Traction Inverters
New Eagle's EV Supervisor is compatible with many inverters including the Rinehart Motion PM Family, Semikron, Sevcon, LS Industries, UQM, Parker, and others.
New Eagle distributes the Rinehart Motion Systems (RMS) Inverters. Visit the webstore for more information. Webstore: Rinehart Motion
Electric Motor
New Eagle is a distributor for the electric motors designed and manufactured by Remy These motors represent a proven technology from a Tier 1 supplier and leader in the electric motor market. New Eagle desires work with the customer to select a specific motor from Remy's diverse motor offerings that aligns with the vehicle level requirements of the application. Examples of common Remy HVH motor solutions:
- Remy HVH 250-090
- Remy HVH 250-115
- Remy HVH 410-075
Please contact us to work with our EV-HEV team to select a motor that meets your needs.
In addition, New Eagle has integrated electric drivetrains from Remy, UQM, Siemens, Parker and LS. New Eagle has experience integrating gearboxes and transmissions from a variety of suppliers. Custom interfaces can be developed through New Eagle to match unique customer motor and gearing requirements and components.
For More Information, go to our Remy Motors page.
DC-DC Converter
Delphi Universal 2.2kW DC-DC Converter
Delphi's 2.2kW DC-DC Converter creates DC voltages in hybrid and electric vehicles necessary to power accessories and the HVAC system. Liquid-cooled, the DC-DC converter operates at input voltages from 216 to 422VDC with a power range to 2.2kW.
Minimum Order Quantity: 1 from New Eagle
Benefits
- In production
- Proven automotive design, reliable even in the harsh environment of the engine compartment
- Highly efficient conversion using synchronous rectification
- Applicable to multiple vehicle platforms without re-engineering
Features
- Analog output voltage is adjustable through CAN serial communication; 11V – 15.5V
- Bi-directional capability supports charging of high-voltage battery
- Over-voltage, over-current, and over-temperature protection with fault reporting
- CAN serial interface
- User Manual including CAN definitions are available upon request with an executed New Eagle NDA
MotoHawk CAN Library
New Eagle has built a MotoHawk library to communicate to and from the DC-DC converter.
More Information
More Information: Delphi 2.2kW DC-DC Converter
Webstore
UQM DC-DC Converter
New Eagle will soon offer DC/DC converters from UQM. These converters have 24 volt output and are available in two different models, one with 60 amp (1.6 kW) output and one with 80 amp (2.2 kW) output.
Common features include:
- 350 VDC nominal input (range 250 to 425 VDC)
- 27.4 VDC nominal output
- Liquid cooled with SAE J1926-10 fittings
- Fused input
- Automatic current limiting
- Lightweight and compact
- Output over-voltage protection and over-temperature shutdown
- Up to 90% efficiency
UQM DC-DC Converter FAQs
Can the voltage be adjusted
- The DC24-80L can be set any place between 25 and 30.5V output. The voltage will be +/- .3V of the selected voltage across load and line conditions. To adjust voltage output the unit must be returned to factory.
- The DC24-60L can be set between 25 and 30 volts. This one can be adjusted using a voltage adjust plug on the outside of the unit.
 UQM DC24-60L |
 UQM DC24-80L |
AC Accessories
Vehicle Controls Accessories
J1772 Sleep Manager (VPIM)
The New Eagle™ Vehicle Power Interface Module (VPIM) provides the necessary circuitry to interface with Electric or Plug-In Hybrid Electric (EV/PHEV) vehicles charging equipment in accordance with the SAE J1772 specification. For more information, click here.
Accelerator Pedal Emulator
In the event that you want to interrupt the accelerator pedal or need to create a pedal signal output, you can try our PWM to Analog Converter.
EV Integration Module
This control module (under development) is a Cost Effective Electrical Systems Integration module for electric vehicles. It will be Model-Based programmable for either prototypes or series production.
Typical Applications:
- Communication/ Diagnostic Gateways *Wake-up on CAN function
- Hybrid electric vehicle systems
- Ancillary Function Control
- Watchdog processing
- Optional J1772 Charger Interface
Input/Output:
- 4 CAN channels
- High and Low Side Drive
- Ethernet
- Sensor Supply
- H Bridge
- Wake on LIN
Embedded Displays
New Eagle delivers programmable and turn-key display applications using our 2" round MiniView or 4" square color (VeeCAN/CANvu) and 4" square monochrome (CANtrak / KAntrak) displays. The VeeCAN 320 can act as both the display and as the EV supervisory controller.
More Information:
Examples:
Webstore:
Vehicle Conversions
New Eagle has supported and executed vehicle conversions on a many different propulsion systems based on customer requirements. New Eagle has developed powertrain controls and conversion solutions for gaseous fuels, dual fuel, electric, and hybrid electric systems.
New Eagle leverages relationships with Tier 1 Diesel and EV component suppliers enabling development across a variety of heavy duty hybrid systems. These systems range in size, performance, cost, and configuration in order to fit the vehicle level performance requirements driven by the application.
Diesel Hybrid Electric Bus
New Eagle has unique experience designing and developing control systems for electric and hybrid electric platforms and conversions. The foundation to support this conversion activity is rooted in the robust hardware and software offerings created for the EV Supervisor.
The bus industry represents an excellent opportunity to utilize the advantages of a hybrid system in order to reduce fuel consumption and operating costs.
New Eagle offers flexible design and execution for a variety Diesel Hybrid Electric Applications designed to fit the customer requirements.
This diagram represents an example series hybrid electric architecture that could be used on a bus application. Let New Eagle's experienced EV/HEV team work with you to develop an architecture that fits your hybrid bus needs.
EV / HEV Aftermarket System for Class 8 Trucks
New Eagle controls engineers worked with Zero Emission Systems to develop an aftermarket hybrid truck system. The system was designed to provide zero emissions while queuing in port and to provide improved gas mileage during normal operations.
With New Eagle's help, Zero Emissions Systems was able to successfully demonstrate the operation of the EV/HEV system on a vehicle. The system was shown to:
- Provide electric vehicle (EV) operation while in port for up to 2-3 hours and at speeds up to 20mph.
- Supply auxiliary systems for up to 10 hours through the electrical system.
- Run in hybrid electric vehicle mode through the PTO during normal operation.
- Improve fuel economy by up to 25%.
- Charge through the engine and regenerative braking.
- Provide high voltage operation from 403 volts to 550 volts.
- Implement a J1939 compatible CAN 2.0 link.
- Provide a 1-1½ year return on investment in fuel savings.
