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Swappable Battery Packs for Agricultural Equipment

ben@haredata.co.uk (Ben Winstanley) — Thu, 03 Apr 2025 11:10:02 GMT

Swappable Battery Packs: A Game Changer for Agricultural Equipment

Introduction

Modern farms rely on machinery that operates for hours on end, with some agricultural tasks requiring up to 12 hours of continuous power daily. In modern agriculture, efficiency and reliability are key, and the need for long-lasting, high-performance power solutions has never been greater. As farms increasingly adopt electric equipment to reduce costs and environmental impact, power solutions must keep up. A swappable battery pack, like the one analysed in our latest study, offers an ideal solution. With the ability to connect multiple packs in parallel, farmers can achieve greater power and capacity without downtime.

What is a Swappable Battery Pack?

A swappable battery pack is a modular power solution. It allows users to replace depleted batteries quickly instead of waiting for a recharge.

Designed for seamless integration, these battery packs can be easily removed and replaced, ensuring uninterrupted operation.

Our Solution

Measuring in at 412 x 79.4 x 269mm, this battery is anything but compact...

It boasts a remarkable peak current output of up to 150A, showcasing its true power!

The latest casing features an IP65 rating, ensuring excellent protection against dust and water.

Equipped with a built-in Battery Management System (BMS), it facilitates cell monitoring, balancing, and reprogramming. We’ve successfully boosted performance, offering 40% more constant current than the previous model and a striking 100% increase in peak power, all thanks to the integrated heatsink that enables active cooling.

This battery pack meets all relevant safety and transportation standards, utilising two different cell types. This flexibility allows FRIWO to manufacture packs more swiftly based on cell availability, while both configurations deliver the same performance and certifications.

FRIWO has also crafted a charger specifically for this pack, ensuring a perfect synergy for efficient charging and extended cycle life.

This battery pack is available individually or as part of the electric powertrain kit.

Technical Specifications

Nominal Voltage: 50.4V (14S configuration)
Battery Capacity: 12P cell configuration providing up to 40.2Ah per pack
Maximum Continuous Discharge: 70A
Peak Output: 150A
Parallel Compatibility: Multiple packs can be connected in parallel to increase total power and capacity
Charging Time: Rapid charging capabilities allow full recharge within 2-3 hours with high-power chargers
Battery Chemistry: Lithium-ion cells for high energy density and long lifecycle
Protection System: Integrated Battery Management System (BMS) for overcharge, over-discharge, and thermal protection

Why Agriculture Needs Swappable Battery Packs?

Agricultural operations involve long hours and demanding workloads. Traditional fuel-powered machines have long dominated the industry, but electric alternatives are proving to be more sustainable and cost-effective. However, one of the biggest challenges of electric agricultural equipment is battery life. A swappable battery system addresses this challenge in several ways:

Continuous Operation: When one battery runs out, another can be swapped in instantly, reducing downtime and increasing productivity.
Scalability: Farmers can connect multiple batteries in parallel, increasing the equipment’s power and capacity to match workload demands.
Reduced Fuel Costs: Electricity is generally cheaper than fuel, and with renewable energy options, farms can further cut operating costs.
Eco-Friendly: With zero emissions, electric equipment reduces the farm’s carbon footprint, making operations more sustainable.
Longevity & Reliability: Advanced battery management systems ensure a longer lifespan and optimized performance.

Parallel Battery Configurations for Maximum Efficiency

One standout feature of swappable battery packs is their ability to be connected in parallel. This means that multiple batteries can work together, increasing both capacity and output. For heavy-duty agricultural tasks, this ensures that tractors, irrigation systems, and other equipment receive the power they need without requiring frequent battery swaps.

For example, a single battery pack may be sufficient for smaller farming tools like electric tillers or sprayers, but for high-powered machinery such as tractors and combines, multiple packs can be linked together to deliver the necessary energy output. This flexibility allows farmers to scale their power needs based on specific tasks, ensuring that even the most demanding equipment can run efficiently without frequent downtime. This adaptability makes swappable battery packs a future-proof investment.

Use Cases in Agriculture

Electric Tractors: Using swappable battery packs ensures that tractors remain operational throughout the workday without long charging breaks.
Irrigation Systems: A reliable power source for pumps and irrigation controllers, keeping crops hydrated efficiently.
Drones & Autonomous Machinery: Many farms are incorporating drones and robotic equipment, which require portable and scalable power solutions.
Harvesting Equipment: Electric harvesters can run longer with parallel battery setups, improving yield efficiency.

Conclusion

Swappable battery packs are revolutionising agricultural equipment by making electric power more practical and efficient. With their ability to enable continuous operation, reduce fuel costs, and scale power needs by connecting multiple units in parallel, these batteries offer a reliable and eco-friendly solution for modern farms. The ability to connect multiple batteries in parallel ensures scalability, continuous operation, and enhanced productivity. As farms continue to adopt electric solutions, investing in this flexible and sustainable power source will be key to a more profitable and environmentally friendly future.

Are You Ready for the Future of Farming?

If you're looking to upgrade your agricultural equipment with swappable battery technology, now is the time to explore the possibilities. Contact a supplier today to learn more about available options or visit our website for detailed product specifications and purchasing information. Stay ahead of the curve and power your farm with innovation!

Empowering Electric Mobility: The Next Leap with Battery Charge Stations for Modular EV Batteries

ben@haredata.co.uk (Ben Winstanley) — Mon, 14 Aug 2023 12:19:02 GMT

In the relentless pursuit of a sustainable and electrifying future, the automotive industry is witnessing a monumental shift towards electric vehicles (EVs).

As we pave the way for cleaner transportation alternatives, a crucial element in this transformation is the evolution of charging infrastructure. Enter the Battery Charge Station for modular EV batteries – a revolutionary concept that's redefining the way we charge our electric vehicles.

Unveiling Modular Batteries: A Paradigm Shift

Traditional EV batteries have served us well, but the dawn of modular batteries marks a transformative moment. Imagine a battery pack that's not only powerful but also modular, allowing for swift swaps and upgrades. This innovative design is a game-changer for electric mobility, eliminating the need for lengthy charging sessions and minimizing vehicle downtime.

Battery Charge Stations: The Heart of the Evolution

At the heart of this transformation lies the Battery Charge Station, meticulously crafted to cater to the unique demands of modular EV batteries.

Here's what makes these charge stations a cornerstone of the electric mobility ecosystem:

Modular Flexibility: These stations are specifically engineered to accommodate modular battery packs, enabling seamless integration and quick battery exchanges. This means you spend less time charging and more time on the road.

Rapid and Efficient Charging: The Battery Charge Stations are designed for rapid charging, leveraging advanced technologies to transfer energy swiftly. With shorter pit stops, drivers can embark on longer journeys with confidence.

Sustainability at the Core: Many of these charge stations are powered by renewable energy sources such as solar and wind, aligning with the broader goal of reducing carbon emissions and promoting sustainability in transportation.

Seamless Integration and User-Friendly Interfaces: Whether you're a fleet manager overseeing a large number of EVs or an individual owner, these charge stations seamlessly integrate with various platforms and offer user-friendly interfaces for hassle-free interactions.

Enabling Fleet Management: For businesses relying on EV fleets, Battery Charge Stations enhance efficiency. The modular battery approach allows for customized fleet management, optimizing charging schedules and reducing operational complexities.

Driving Collaborative Innovation: The development of Battery Charge Stations for modular EV batteries is a result of collaborative efforts between manufacturers, researchers, and the wider EV community. This collaborative spirit is propelling the industry forward, creating a ripple effect of innovation.

The Road Ahead

The advent of Battery Charge Stations for modular EV batteries represents a significant stride in the evolution of electric mobility. As we look ahead, envision a network of these stations sprawled across cities, highways, and remote locations, effectively erasing range anxiety and promoting the adoption of EVs on a grand scale.

This transformation goes beyond vehicles – it speaks to a global shift towards cleaner, sustainable, and interconnected transportation. It's a reminder that innovation is not merely about advancements in technology; it's about catalyzing positive change for the world we share.

So, buckle up for the journey ahead. The road to a greener, electrified tomorrow is paved with innovation, collaboration, and Battery Charge Stations that promise to reshape the way we move, one charge at a time.

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Innovative Power Supplies and Drive Systems for E-Mobility

ben@haredata.co.uk (Ben Winstanley) — Mon, 31 Jul 2023 10:40:04 GMT

Unparalleled driving pleasure: Next-level electromobility

The key to a perfectly functioning overall system is the precise selection and detailed matching of individual components. To make sure that the process is a success we offer you a complete package: As a provider of drive technology systems we can deliver all the components required for a modern electric drive train from a single source – including the required control and service software.

Digitally controlled drive systems

Our portfolio includes a modular system consisting of the display, motor control unit, drive unit, battery pack, and charger, with the option of digital control and monitoring. Our in-house software allows the behavior of individual components to be amended – whether by the vehicle manufacturer on the production line or by the driver with an app in everyday use.

The software can be used to configure the behavior of individual components completely independently, giving your vehicle its own character that sets it apart from standard solutions. You can offer the user different driving profiles and fully brand the vehicle’s digital displays in line with your corporate design, to create a unique customer experience and strengthen brand recognition. And, last but not least, you can intelligently network your vehicles to gather more knowledge about your product with each additional kilometer driven, and allow wireless updates.

You call it a unique driving experience. We call it system solutions made by FRIWO.

FRIWO Drive System

Our drive systems meet the highest international quality standards and are known for their reliability and robustness. We ensure that every product is subject to our strict quality controls to guarantee long-term and reliable functionality.

FRIWO E-Bike

At FRIWO, we understand that the power supply of an e-bike is crucial. That’s why we offer customized solutions that are specifically tailored to the requirements of your e-bike model.

LEAKED! Santas Electric Sleigh

ben@haredata.co.uk (Ben Winstanley) — Mon, 20 Dec 2021 09:44:22 GMT

Oh No!

The Secret Blueprints for Santa's New and Improved 2021 sleigh have been leaked!

Santa's ditching those old reindeer and is stepping into Christmas using a new e-sleigh...

a combination of FRIWO Battery Power & Christmas Spirit is sure to get him around the world and back in no time!

Success Story - Brekr electric moped

ben@haredata.co.uk (Ben Winstanley) — Wed, 24 Mar 2021 16:51:47 GMT

E-mobility start-up relies on a powerful drive and control system from FRIWO for its electric moped.

Brekr started developing Model B with the aim of launching an electric moped that surpasses all other models in terms of design and technology. The two start-up founders Jasper Hagedoorn and Niels Willems were looking for an experienced partner for the technical implementation. After testing numerous battery systems, controllers and motors, FRIWO emerged as Brekr’s system partner of choice.

H ard Shell, Soft Interior: Brekr Model B Offers Maximum E-Mobility Driving Comfort

If you want to develop a groundbreaking technical product, you need competent partners. When the two e-mobility enthusiasts Jasper and Niels wanted to turn an ingenious idea into a highly innovative product in 2017, it soon became clear that having reliable partners is essential for technical feasibility. But one thing at a time.

Jasper and Niels felt that aesthetic electric mopeds or scooters had not been produced for a long time. Most products looked more or less the same.

In addition, many models had a fuel tank – not a fully developed e-mobility concept.

That’s why Jasper and Niels founded Brekr. With the Brekr Model B, the start-up developed an electric moped that did not exist in such a form.

The form should follow the function, with Brekr focusing on minimalist design and the art of omission – less is more!

Brekr started developing Model B with the aim of launching an electric moped that did not yet exist in such a form. Brekr combines the past with the future in a unique and functional design.

Rough shell meets driving comfort and state-of-the-art technology. An electric moped that puts a smile on the faces of e-mobility fans.

No fuel tank, but rather a low-positioned battery box. This means that the Brekr Model B has a low center of gravity, resulting in improved handling qualities.

At the same time, proven design principles from the world of mopeds and scooters have been adopted to ensure a recognition effect.

The mission of Brekr is to intelligently combine proven with radical innovation.

Powerful Motor, Maximum Battery Capacity and a Smart Controller: Brekr Relies on FRIWO

Brekr started searching for the most important technical components during the design process. The team relied on the long-standing experience gained by its members in technical development. Although there are some similarities between a 45 km/h bike and an electric moped, the heart of the drive and control system beats differently. Brekr needed a more powerful motor, increased battery capacity and a controller that could seamlessly control them both.

The search for technical components took Brekr right across the world – from Europe to North America and Asia. The systems and components that initially appeared to be suitable on paper were built into prototypes to test their functionality, reliability and performance in practice.

Tech Specs

Components Used

Motor Controller

Software

35E Battery Pack

Summary

After testing numerous battery systems, controllers and motors, FRIWO emerged as Brekr’s system partner of choice. As one of the few potential partners, FRIWO stood out from the crowd as a supplier of complete system solutions. This distinguishes them in this relatively young market and makes FRIWO a reliable partner for Brekr. They have been able to provide all the necessary information at all times. After just a few discussions, FRIWO was able to provide Brekr with excellent support in further developing the system in order to achieve optimal functionality.

The Brekr team confirms:

“We directly felt FRIWO’s desire to develop a first-class product with us. The enthusiasm for the Brekr Model B was sincere. Together we turned the design into a reality. We have been working together for some time now and have found the cooperation to be seamless, which will only serve to boost our confidence in them in the future.”

Like FRIWO itself, Brekr also relies on long-term cooperation with partners who work together to further improve what has been achieved and create new innovations. Brekr and FRIWO are an excellent match.

Can our powertrain technology help you too?

Product Videos

Success Story - TU Graz

ben@haredata.co.uk (Ben Winstanley) — Wed, 24 Mar 2021 16:19:32 GMT

About TU Graz

The Institute for Software Technology (IST) at Graz University of Technology researches methods for navigation in unstructured environments. The institute is actively involved in interesting research projects such as RoboNav, ROBO-MOLE or ELROB. With ARTI, graduates of the institute have founded a start-up that aims to further develop robots for practical use in transport logistics.

Further information: tugraz.at/institute/ist

Graz University of Technology Simulates a Manned Mission to Mars with E-Mobility

The future of autonomous electric mobility is multifaceted. Graz University of Technology is fulfilling this reality by developing a universally applicable research vehicle that can be used both for simulating a mission to Mars and for rescuing people buried in avalanches. FRIWO accompanies this exciting project and provides strategic advice and supplies the drive and control technology.

Autonomous Off-Road Navigation: TU Graz Places Special Demands on Electromobility

Autonomous driving in areas for which there are no maps is a complex challenge. Professor Gerald Steinbauer and Richard Halatschek from Graz University of Technology have made it their mission to develop electrically powered vehicles that drive independently in rough terrain.

How does an exploration vehicle find its bearing on Mars?
How does a reconnaissance vehicle navigate through avalanche terrain?
How does a self-driving robot move in hazardous material situations?

The Autonomous Intelligent Systems research group at the Institute of Software Technology (IST) of Graz University of Technology, headed by Professor Gerald Steinbauer, has been working on questions like these for many years. Today, a mission to Mars still sounds like a distant future dream.

However, using a very concrete practical example in the city centre of Graz, the research team impressively demonstrated which use cases are made possible by electrically powered vehicles in the field of autonomous navigation.

In cooperation with Austrian Post and Energie Steiermark, TU Graz implemented a showcase in which a robot independently delivered parcels to addressees in the city centre of Graz.

But a showcase is just a showcase - and the research team from Graz University of Technology is pursuing a greater mission, namely a multifunctional vehicle that can be used in future research projects. It should have off-road capabilities, be a certain size and have a decent range.

FRIWO Offers TU Graz Maximum Flexibility and Personal Service in Vehicle Development

The basis for the new multifunctional vehicle was provided by the commercial electric vehicle Jetflyer from the Styrian vehicle manufacturer e-netic GmbH, which was used in the showcase project in the city centre of Graz. The research team equipped the vehicle with electronically controlled steering, brakes and accelerator, enabling “drive-by-wire” control of vehicle functions.

Stereo cameras, inertial sensors, laser sensors and a control computer enable autonomous navigation in unmapped areas. The computer runs specially developed

software that processes the sensor data and enables autonomous navigation in impassable terrain. This way, the development team combines the best of both worlds: automotive engineering meets robotics with the goal of automating vehicle control to such an extent that automated navigation is possible.

“A decisive prerequisite for this is freely configurable drive and control technology. With our system solution, we provided conceptual advice to TU Graz from the very

beginning and supported the research team in the technical implementation,” says Henrik Vogler, Head of R&D E-Mobility at FRIWO. One of the biggest challenges was to build up effective torque even at low speeds. This is because the research vehicle of Graz University of Technology is not a high-speed E-mobility racer, but rather a vehicle designed for maximum precision.

The driving signals of the autonomous control addresses four motor controllers via a central CAN bus. The speed can be controlled irrespective of the driving speed of the research vehicle – a complex requirement that only very few E-mobility system providers have achieved.

“With FRIWO, we have found a system partner who has supported us in a cooperative manner from the very beginning. Our requirements do not correspond to the usual industry standards. In this respect, we very much appreciate the extra effort that FRIWO invested in providing advice and support”

- Says Richard Halatschek, who heads up the project at Graz University of Technology.

The Brain behind the Electric Powertrain

ben@haredata.co.uk (Ben Winstanley) — Wed, 24 Mar 2021 12:53:49 GMT

The Brain behind the Electric Powertrain | Focus on the Motor Controller and Software

A combination of the motor controller and software are integral to the FRIWO Electric Drive Train because each of the components such as the battery pack and the brushless DC motor require a good brain to get the best out of them. Like a person, the better the brain, the more intelligent it is and the more capable that person is of completing a task, the same could be said with the drivetrain!

We have focused a lot on the battery packs and the brushless DC motor of late but the real hero is the integration between the motor controller and the software, the capabilities that they offer and I want to focus on the brain within this blog.

So, what is the Motor Controller?

The motor controller is the black circular device that can be seen mounted on the motor above.

This device does exactly what the name would suggest... Control the Motor!

Operating at 48V, this device was specially developed for use in light electric vehicles. With a continuous output of 6kW and a peak power of up to 12kW.

Thanks to the automatic teach-in function, the controller forms a powerful unit with the motor within a very short time.

Our field-oriented control system with highly efficient control algorithms then ensures a unique driving experience.

Key features

Safety and reliability

What’s more is that the motor controller recognises malfunctions that may occur during operations and will shut down quickly deciding whether to tune down the power so not to damage the system.

Size Vs Power Rating

Best in class and can be installed almost anywhere on a electric vehicle allowing installation in tight spaces on vehicles such as electric scooters, quad bikes, or even Go-Karts.

Flexible

Will control and manage any 3 phase brushless DC motor, equipped with digital hall sensors.

Grid Compatible

Will manage 40 battery packs in parallel increasing overall capacity.

Proven Performance

The motor controller and software was used for a high pressure pump in the Porsche LMP1 during 24hr race of Les Mans.

What Are the Software Capabilities?

This intuitive piece of electric vehicle software can be configured by the user to deliver exacting performance depending on the user requirements.

For example if you run a fleet of Go-Karts and in the morning you have a children’s party booked you can create a profile setting parameters to limit speed and torque in order to make the go-kart child compatible and then you can set up a separate profile perhaps to increase speed and torque, whilst adjusting braking for the adult group booked in later. After initial setup, this operation is a simple toggle between profiles via a button or on the app.

Or you could have a fleet of scooters and need to conserve battery power as much as possible so the need to maximise running time. There are combinations of parameters that can be set to achieve this so let’s say you need to ride your vehicle over a distance and you know it is mainly downhill you could actually set up a profile to re-coup energy and put this back into battery to give you additional running time and what’s more is that profiles can easily be selected using the app making the system straightforward to access and manage.

Should you edit parameters that result in a negative effect on the behavior of the controller then the safety element kicks in and these commands are usually intercepted or parameter changes are limited to safe values. Without drilling too much into the software set up and listing every tab and every parameter I have included the image above to highlight the interface once logged in, and the start-up is very straight forward as you move along the top tabs, selecting parameters as necessary from a selection of options, inputting values ranging from 0-100 in some cases or 1-10 in others.

Applications

There are many applications that the FRIWO Motor Controller and Software can power and I have mentioned the obvious ones above but the system is very flexible and was recently selected to solve an issue with a large water pump used with an external motor and the problem was that the flow needed to be limited. The motor in its current state was generating too much power and therefore the pump was running too quickly. The motor controller was implemented, parameters were set up and the motor was limited to a specific speed, reducing the speed of the pump.

Other applications include e-bike, scooters, Rickshaws, Quad bikes, Golf carts, Drones, Conveyor belts, Stairlifts and quite frankly, any application that requires a motor and there needs to be an element of control.

To conclude, the combination of the FRIWO motor controller and software is integrated to fine tune any battery and motor combo and will be the brains of your application to offer the flexibility to meet ever changing requirements.

Lithium ion batteries to power the future!

ben@haredata.co.uk (Ben Winstanley) — Sat, 01 Feb 2020 11:02:31 GMT

Li-ion Batteries Usage is set to grow at an unprecedented rate!

Li-ion requirements in 2020 and the decade ahead is set to rise at a supersonic pace due to the electrification of almost everything.

Historically, Li-ion Batteries have been powering consumer devices but now with the world fixated on carbon neutral targets this has shifted into transportation and electric utilities and it seems there is a race to incorporate Li-ion into new technology such as cars, motorbikes, other vehicles robotics and an array of warehouse technology. With such demand forecast it is inevitable that there is a scramble to find a solution that will offer more power than the current Lithium Ion battery but for now it is here to stay.

The focus should remain on improving current battery performance and one consideration could be to utilise the current battery technology in a smarter way. Use smart CAN-Bus interfaces and software to set limitations and calculate state of charge. Adopt Li Ion batteries that have built in technology such as short circuit protection, over and under voltage protection and recovery features. Combining this with over- temperature protection will enable maximum usage of the Li-ion battery whilst maintaining safe discharge.

Another consideration to increase capacity is to combine several batteries in a parallel formation and use CAN-Bus technology to distribute the power and therefore building a larger capacity battery grid.

With a couple of firmware tweaks the batteries could be synchronized and will deliver a larger amount of power.

The visual shows 20 packs to give a 804Ah Capacity.

However can safety combine 50 packs which would give you 2,010Ah!

Whilst improving the battery performance, you may want to consider charge speed. To improve speed in a smart Li-ion battery you should focus your attention to the battery charger itself. Select a reliable battery charger that is built with Tier 1 components which delivers the correct amount of current. You should use a battery charger that has the ability to monitor the health and cell state of the battery. Using that information a smart charger will use the right amount of current to charge the battery in the quickest possible time without damaging the battery cells.

There are a number of ways to take care of your Li- ion battery and increase the life cycle:

1 – Keep your batteries at room temperature if they a regularly charged and discharged.

2 – Think about increasing the battery capacity rather than carrying a spare - Surprisingly a battery that isn't used often and stored fully charged will see a reduction in capacity and performance quite rapidly.

3 – Allow partial discharges and avoid full discharges.

4- If you have a battery as a spare for example, discharge it to about 40% and store at roughly a refrigerator temperature.

If you are embarking on a project that requires Li-ion batteries, chargers or are looking at electrifying a vehicle please contact Haredata Electronics by emailing hello@haredata.co.uk or give us a call on 01423 796240 - Let Haredata Electronics power your success!

Haredata Application - Robotic Horticultural Products

Fri, 13 Dec 2019 16:03:45 GMT

Battery Charger meets extreme temperature requirements!

A major global manufacturer asked us to look at developing a range of battery chargers for their latest project, the next generation of robotic horticultural products. The products are built at the customers UK facility, but much of the engineering and specification work was in association with the European based product management team.

Application Specific Power Supplies

The application specific requirements were extreme by any standards:

The working temperature range specified was from -30°C to +40°C and we carried out exhaustive testing to build this requirement into the customer specific design. The Chargers also had to be IP rated as they would be subject to the extremes of weather throughout the European region from the Barents Sea to the Mediterranean. To meet this operational concern we developed a partial potting process for manufacturing to ensure compliance. The Chargers also had to be UV tolerant and suffer minimal degradation over an extended lifetime. Extensive testing to confirm compliance was carried out both in the FRIWO R&D area and at the customers own test facilities. Despite these high parameters, there were also very strict condensation limits imposed at most extreme operating conditions at the design stage.

Finally, despite the somewhat rugged nature of the application, FRIWO still offered a nominal 200K hour MTBF as they do across the whole range of PSUs and Chargers. The customer now takes FRIWO Chargers for the majority of their robotic product range after successful and collaborative engineering work across the range.

We can help with your application too...

Haredata Application - Assisted Living

Wed, 11 Dec 2019 12:05:42 GMT

How Haredata help with assisted living

We approached a global provider of assisted living products and services. The customer had already purchased a quantity of high quality globally approved power supplies from Haredata. Most of the existing systems used power supplies with linear rather than switch mode technology.

We were able to offer the latest technology environmentally compliant switch mode PSUs offering a significant energy efficiency improvement for the end users.

The application required power supplies with an exemplary level of safety and we offered products compliant with IEC60950, UL60950 and EN60950.

The customer distributes systems on a global basis so required a product with global safety approvals from a supplier with experience of managing the approvals process. These particular requirements were driven in part by the fact that the systems being powered by the FRIWO PSU are used in a domestic environment, often by vulnerable users. Another major concern was to provide enhanced surge and lightning protection.

The application requires the power supplies to be “live” 24 hours per day, almost anywhere in the world. We offered an enhanced surge protection of 6kV in order to satisfy this requirement and concern.

High Specification Power Supplies

This was a customer specific requirement that required a higher than standard specification. Reliability and high MTBF were also of major concern, and the FRIWO range was selected after evaluation of several competitive products.

The customer has subsequently taken delivery of over 500,000 pcs to this specification.

We can help with your application too...

Challenges you may face when developing an Electric Drive Train

Wed, 27 Nov 2019 12:59:53 GMT

What challenges to overcome when developing an Electric Powertrain?

The world faces enormous challenges when it comes to energy and climate change. Energy-efficient Electronic Powertrains are contributing to combating some of these challenges. The race is on to develop efficient, economical and dynamic Electronic Powertrains and some of the figures been spent on research and development by companies based around the world is huge.

It appears that most countries have bought into reducing air pollution and the UK are one of those countries that want to be at the forefront of electric technology and has a target of ‘zero’ greenhouse gas emissions by 2050 as per this BBC article .

If the world is serious about meeting global energy and climate change challenges then replacing diesel or petrol engines with an efficient Electronic Powertrain is one of many innovations required to help reach that goal.

Modern Electronic Powertrains are a relatively new concept for some industries, especially the automotive industry and engineers are challenged with designing affordable, efficient and high-performing Electronic Powertrains as the industry undergoes a technological evolution.

The automotive industry is one area spending big to revolutionise the industry but in certain machine applications, Electronic Powertrains are in some cases the only option suitable due to the high torque demands at wheels and controllable requirements.

The Electric Powertrain is considered a relevant and competitive option to replace hydrostatic and hydrodynamic powertrains to increase energy efficiency. In mobile machines the Electric Powertrain could also improve the manoeuvrability and increase control accuracy so there are numerous industries that can benefit from the development of the system.

Whilst various industries are striving to develop leading Electric Powertrains, FRIWO have been busy in development and have combined all of their in-house speciality skills around power management and battery management to develop an Electronic Powertrain designed for mid-size vehicles and machinery. The FRIWO Electronic Powertrain is tried and tested and is already powering a fleet of hire scooters in Europe and due to the impressive system integration, software capabilities and agility, the fleet is co-ordinated entirely via an app.

The largest challenges faced developing an Electronic Powertrain can be split into 3 main segments:

1 - Range and charging speed

To meet range and acceleration targets, manufacturers need to work out battery sizing and explore motor and battery design trade-offs because a higher performing motor can lower the overall cell count for the battery pack. This is a very complex area especially when it comes to developing an Electronic Powertrain for high end vehicles wanting to quickly charge but yet reach distances of 200 miles plus.

Companies must develop and validate optimal charging algorithms and understand the impact of fast charging on their battery pack life. During charging, if the battery pack or charger temperature exceeds a critical temperature, the vehicle controller will reduce charging speed, lengthening the charging time. Thus, battery pack and faster charging electronics design, algorithm development, and thermal management go hand-in-hand.

2 – Performance and Lifetime

In the early part of the FRIWO development it was recognised that in-field reliability of the battery, motor, and power electronics were major concerns. It was recognised that maximum temperature and its distribution during in-field operations is a life-limiting stressor for components. There was a real need to account for not only material properties, but also tough-to-measure non-uniform distribution of current, voltage, magnetic flux, and temperature in these components.

Multi-domain data exchange within the FRIWO software at the early system design concept stage was therefore crucial. Integration and system-level exploits, if left for the later stages, would have resulted in design iterations and system integration problems.

3 - Integration

Optimising the integration of mechanical and electrical components into one Electronic Powertrain marrying each component of the Electronic Powertrain is the key to its efficiencies. Innovative simulation and optimisation software tools should be used early in the concept phase to assess optimal design variations.

At present, most Electronic Powertrains available comprise of separate entities such as the motor, battery, drive train and a vehicle control unit which are usually bundled together and what I have noticed is that taking this approach usually mean projects often run over or spiral over budget because work then starts on integration and it is the equivalent of drawing house building plans after the house is built.

The FRIWO Electronic Powertrain has been designed with integration in mind right from the start and designed with the end user in sight. All components are tied into the software and in effect the whole Electronic Powertrain is powered by the software arming the end user or manufacturer with the flexibility to set parameters to suit the function of the vehicle or piece of equipment that it will power.

See the Electronic Powertrain in action!

The video shows a live demonstration of a Go-Kart containing the FRIWO Electronic Powertrain and it is been controlled by a mobile phone app via bluetooth.

T he app in this situation allows you to control the vehicle output parameters as well as monitor vehicle performance using real time data.

To Summarise

There are many complex areas to developing an Electronic Powertrain. You simply cannot take the best components, bundle them together and expect to develop an efficient solution in super quick time. Haredata Electronics based in the UK have the perfect solution for mid-size vehicles developed by their German partners, FRIWO. The FRIWO Electronic Powertrain is very flexible and will provide the beating heart to any vehicle or piece of machinery, allowing you to focus on its design, reducing long term project costs, removing integration headaches and allowing efficiencies right across the solution!