Case Study – Hyperflex M-PDU Feasibility Study

PROJECT OVERVIEW

Conceptually, the M-PDU is a modular, scalable and configurable high voltage, high current PDU providing the electrical integration hub for low and mid-volume vehicle programmes looking to integrate battery electric and fuel cell powertrains using commercial off-the-shelf components.

HyperFlex M-PDU was a technical and commercial feasibility study into whether a PDU could be modularised, offering an alternative approach to the bespoke PDU designs currently required by low volume and niche vehicle manufacturers, impacting both the lead time and affordability of vehicle development.

FEASIBILITY STUDY

Hypermotive’s research showed that, while no single PDU design could cover all applications, a limited range of off-the-shelf products could suit most scenarios explored. There is also potential for modularisation by re-using parts of the PDU design across different customers – either through creation of a common software framework, or through modular sections of hardware.

Key outcomes show good opportunity exists to modularise certain aspects, such as PCBA and software design, but further research is required into the more complex aspects for modularisation such as the physical ‘building block’ approach to internal hardware, connectors and enclosures.

OUTCOMES

• Key project outcomes include:
  • Confirmation that no ‘one-size-fits-all’ is possible for PDUs – either hardware or software
  • Identification of significant opportunities to modularise certain aspects of the PDU to create customisable platforms
  • Development of a configurator tool providing a means to capture requirements and create product specification
  • Categorisation of vehicles across a range of low volume and niche applications providing a database of common requirements, enabling targeting and banding of core product attributes
  • Understanding modularisation opportunities from the categorisation process
  • Enhanced understanding of current PDU capabilities within Hypermotive, enabling improved customer targeting and business development.

NEXT STEPS

• The positive outcomes from the feasibility study provide a pathway of next steps to build upon the value of this work:
  • Continue the development of configurator tool for functionality and application requirements
  • R&D planning for identified high-value and accessible systems for modularisation – PCBA, software
  • Create project scope for further technical feasibility deep-dive into the more challenging attributes identified – the physical ‘building block’ approach for internal and external hardware
  • Review funding opportunities to further develop the above R&D and feasibility activities for modular software and hardware systems

Importance of NVN funding

The NVN funding for this project has been key to enabling the research activities within this feasibility study. As an SME, Hypermotive have limited resources to conduct self-funded R&D and the provision of external funding from NVN allows the wider spread of resources, de-risking future R&D investment from both internal and external parties.

The independent nature of the funding also creates and retains IP within Hypermotive, offering the opportunity for greater retained technical and market knowledge value and wider potential exploitation opportunities.