Engineering Services
Simulation | Design | Prototyping | Testing
Your Engineering Partner for Tomorrow's Challenges
The core of Vaionic is the Team, 85% of which are specialists with a technical background. Our hands-on mentality and solution-oriented approaches ensure a technology- and customer-focused approach. With 6 years of experience in electric motors and power electronics development, Vaionic boasts a diverse skill set, enabling us to exceed industry standards. The streamlined structure and agile project management drive the development of novel motor technology.
The development process at Vaionic covers following phases: Simulation, Design, Prototyping and Testing.
A closer look at the cycle reveals that the process steps of neighboring phases work closely together, constantly exchange information, and are sometimes carried out simultaneously within the Vaionic team. This is the key aspect that enables us to lead complicated developments from start to finish.
Simulation
eMachine
Electromagnetic FEA Electromagnetic simulation of eMachines in ANSYS.
Structural & Thermal FEA Static + dynamic structural, as well as thermal simulations in ANSYS.
Computational Fluid Dynamics Fluid dynamic simulations for cooling system and ventilation loss optimization in ANSYS.
Power Electronics
Control Algorithm and Topology
Power Electronics and Motor Filter simulations in PLECS.
Transistor Simulations Switching behavior of transistors.
Computational Fluid Dynamics Fluid dynamic simulations for cooling system optimization.
System
eDrive System Performance and energy consumption simulations on system & vehicle level, using MATLAB models.
Design
eMachine
eMachine Design 3D modeling of e-machines, modules (rotor, stator, housing) and cooling system.
Materials Science Analysis of mechanical and chemical properties of plastic, metal and ceramic materials.
Power Electronics
Power Electronics Design Stackable PCB design with Power Unit, Gate Driver Unit and Controller Unit.
Motor Filter Design and loss-analysis of motor filters (motor chokes and sinusoidal filters).
System
System Design and Integration Mechanical architecture design for e-drive solutions.
Prototyping
eMachine
E-Machine Stator & Rotor Prototyping
In-house coil winding production, contact soldering/welding and RTM (resin transfer moulding) process. Rotor assembly, balancing, final assembly.
Power Electronics
Power Electronics Prototyping Power Unit, Gate Driver Unit, Controller Unit, Motor Filter Unit, Heat Sink, Power Electronics Housing - manual mounting and assembly.
Tools & Machines Production Development of tools, devices and processes, in order to take full control over the entire production process.
System
Final Assembly 2in1 system assembly (e-machine + inverter)
Test Bench Development Design, mechanical simulation, programming and build-up of test benches for 2in1 systems, high voltage e-machines, power electronics and components.
3D Printing Flexible and cost-effective production of components and devices.
Testing & Validation
eMachine
Vibration Analysis Structure-borne and air-borne noise evaluation.
Geometry Measurements Ensuring precision and accuracy through dynamic optical and tactile geometry measurements.
Insulation & Partial Discharge Measurements Analysis of dielectric strength and partial discharge in high-voltage applications.
Thermal and Electrical Ageing Tests Long-term effects of temperature and electrical stress on materials and components.
Hydraulic Tests Pressure volume flow characteristic, peak pressure validation tests.
Power Electronics
Initial Operation Tests Examination of PCBs and testing of basic safety features.
Double Pulse Tests Analysis of switching losses and behavior of transistors.
Calibration of Measurement Sensors Checking interference suppression and calibration of current, voltage and thermal sensors.
Load Tests Analysis of thermal behavior and determination of overall losses with passive loads.
Verification of Controller Parameters
Verify behavior of speed and current control of the motor.
System
Insulation & Partial Discharge Measurements Analysis of dielectric strength and partial discharge in high-voltage applications.
Performance Measurements Peak and continuous power, torque and efficiency maps.
Vibration Analysis Structure-borne noise evaluation
Temperature Curves Temperature measurement of all components of e-machine and power electronics
Hydraulic Tests Pressure loss, volume flow and temperature measurement in cooling systems.
Drag losses & Back-EMF Tests Torque and voltage measurement of the e-machine prototypes.
Our Partners & Projects
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