Electric and hydrogen vehicle
Electric vehicles are one of the main bets for automotive companies, with an ever-increasing demand and a market with a huge growth potential. Currently, many policies and solutions are being implemented to promote sustainable and environmentally responsible mobility, with a corresponding reduction in emissions.
Research and development related to the sustainability of electric vehicles is becoming increasingly important. For this reason, CTAG has used its experience and competences to design and set up a specific laboratory for electric and hybrid vehicles, inaugurating in 2019 the EV LAB, a laboratory to develop, test and validate the electric vehicle, its components and energy storage systems.
Hydrogen is one of the great challenges facing the automotive sector. The development, research and technological innovation around this new sustainable propulsion system is a fundamental part of CTAG's strategy.
EV LAB
- Cutting-edge laboratories for the testing, calibration, characterisation and validation of powertrains, battery systems, power electronic converters, electrical machines, thermal and electronic management systems, and sub-components for electric vehicles.
- Characterisation, performance, reliability, durability and safety tests according to manufacturer's regulations (OEM and TIER-1) and national and international standards.
R&D in battery systems
R&D activities on new battery systems for stationary applications and electric vehicles, considering project specifications and implementing improvements in key aspects.
Examples would be the integration of new cell types, the search for new materials to reduce weight, the optimisation of thermal management, the development of faster recharging and bi-directional capability, the incorporation of new functionalities into the BMS, design improvements to increase fire safety, increased energy density (kWh/kg), and the ability to facilitate recycling or second life uses.
Examples would be the integration of new cell types, the search for new materials to reduce weight, the optimisation of thermal management, the development of faster recharging and bi-directional capability, the incorporation of new functionalities into the BMS, design improvements to increase fire safety, increased energy density (kWh/kg), and the ability to facilitate recycling or second life uses.
Power Electronics Converters and Battery Management System (BMS)
We develop R&D activities in:
- Electronic battery management (BMS), developing algorithms to optimise the charging process, enable bi-directional charging, extend battery life or optimise thermal management.
- Power electronic converters oriented towards powertrains and battery chargers, in areas such as characterisation, control and topologies. Our development competences are model-based development, rapid control prototyping (RCP) and real-time simulation with hardware-in-the-loop (HIL).
e-Powertrain
- Characterisation, control and calibration of the powertrain thanks to the development of algorithms for optimising and improving performance, as well as the availability of a state-of-the-art axis bench that allows us to evaluate the complete powertrain and its components. Within the calibration and control process, we cover various topics such as vector control and thermal mapping.
- We have a laboratory where we carry out durability, fatigue, ageing and life cycle acceleration tests.
- We perform vehicle instrumentation/sensors, assembly, disassembly, analysis and diagnostics. In addition, we have tools to develop electrical (HV/LV), hydraulic and mechanical installation systems, as well as CAD design and rapid prototyping capabilities.
- We develop one-dimensional computational systems (system simulation) in order to facilitate tasks such as modelling, sizing, calibration and virtual control of the electric powertrain. The result is a significant reduction in the costs associated with experimental testing and the advantage of being able to emulate vehicle conditions and cycles in a virtual environment.
- From Road-to-Lab. We use both Software and Hardware-in-Loop (HiL) to simulate road conditions and data in an experimental environment (the powertrain test bed) in which to reproduce and analyse the demands of a complete electric powertrain under specific conditions. Different drivers, vehicles, roads and cycles as well as different conditions are simulated and reproduced. The aim is to reduce road tests and to be able to reproduce them with high repeatability in the laboratory by controlling the influencing parameters.
Thermal Management
CTAG's development capabilities cover thermal management systems, thermal modelling (CFD) and test bench work for power electronics.
- We develop innovative solutions focused on thermal comfort and energy efficiency, combining heating/cooling technologies. The aim is to increase the autonomy and service life of the components.
- We have advanced modelling (CFD), simulation, prototyping and testing skills to support our activity.
- Our projects focus on cost reduction, battery temperature homogenisation, battery preheating in cold climates, heat recovery from power electronic converters, or optimisation of energy use, for example, through cabin thermal management based on user perceptions or the integration of specific heat pumps.
- Diagnosis and development of thermal management algorithms for Powertrain. We analyse and develop control strategies for thermal management using simulation tools, road data analysis and dynamometric bench testing.
Structural development of electric vehicles
The development and optimisation of specific structures for hybrid and electric vehicles is one of the great challenges of the automotive sector and, therefore, one of the areas in which CTAG is active.
We promote and carry out R&D activities aimed at weight reduction, recycling or reuse of materials, the introduction of new materials with specific functionalities and the structural protection of both passengers and the battery.
We promote and carry out R&D activities aimed at weight reduction, recycling or reuse of materials, the introduction of new materials with specific functionalities and the structural protection of both passengers and the battery.
Component validation plans
- Design, planning and execution of validation plans for automotive components according to manufacturer regulations (OEM and TIER-1) and national and international standards.
- Client advice on test specifications, regulations and standards applicable to the product.
- Design and manufacture of validation tools, equipment, test benches and technical installations.
- Documentation and critical analysis of failures, aimed at product improvement.
Hydrogen vehicle
- H2 gas supply system.
- Securised box for inertisation and test preparation of H2 fuel cell vehicles.
- E-Axle adapted for hydrogen vehicle hybrid powertrain.
- Development of algorithms for optimisation and improvement of the battery-battery hybrid powertrain....
