Freudenberg e-Power Systems

Freudenberg e-Power Systems

Our Problem

Freudenberg e-Power Systems builds highly complex fuel cell systems – 10.000-15.000 single signals with up to 500 fuel cells to be controlled. The tests for such systems involving the real hardware are expensive and often dangerous, especially in the prototyping phase. It is also not always possible to access and stimulate all the inputs to generate fault conditions.

The Solution

The miniHIL simplifies our testing process dramatically:

• miniHIL is scalable – due to enormous number of signals, we had to develop our own hardware extension but the miniHIL software is the same
• tests and test components are reusable – develop once and create multiple instances
• thanks to complete environment simulation, we can test our software as a black box but without the dangers of the real world hardware setup
• we can test safety features by error injection because we have access to all of the system’s inputs
• cooperation with PROTOS is straightforward, professional and solution oriented

Project Example 1 – galvanically isolated DC/DC converter (150 kW)

• microcontroller’s environment simulation
• no need for an actual 150 kW electrical load
• no dangerous voltages present in the system
• the complete test system fits on a developer’s desktop (the original one weights 100 kg)
• test of complete software

Project Example 2 – fuel cell control unit for yachts, buses and cruise ships

• test of the actual software in the completely simulated environment (sensors, actuators, integrated circuits like FRAM memory, ADCs, DACs, temperature sensors)
• no expensive hardware required
• easy access to every signal in the system
• error injection tests possible on every interface (CAN, SENT, I2C, SPI, …)
• restbus simulation (CAN)

Fuel Cell Systems

Freudenberg e-Power Systems website

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