Product Development

Concept, Creation, Completion – Three Tiers of our Product Development

  • Component development with testing

    We develop and manufacture core components for heating and cooling in-house.

  • System Development with Testing, Simulation, and Software

    High-performance and durable components are at the center of our continuous improvement.

  • Application technologies with field tests

    Products and systems will be integrated into the specific vehicles to ensure the desired functions are met entirely.

From four competency focuses, our products, systems, and development tools arise for proper layout and validation in accordance with the wishes of our long-term and high-expectation customers, which serve premium markets in the world of mobility for persons as well as goods – from bus, across municipal vehicles, rail, military, through to construction, agricultural, and forestry machinery.

Our vision is to offer solutions, which, at unique levels of component performance, combine the value of long product life spans with low costs. At the systems level, to offer intelligent integration, pairing ultimate comfort for end-users with high-efficiency for the vehicles to go further than before. This vision is best defined by our leading slogan “e4c – efficiency for comfort”.

The development of our heat pump system for electric buses proves this in many ways. At 0-emissions, we reduce the energy requirements for heating, for example, at -10°C (14°F) by about 60% as compared with traditional sources like direct electrical heat. This leads to an increase in overall driving distance on a single-charge by about 40% when in heating mode. Moreover, the energy requirement across an entire year, including cooling, is also reduced by about 25%.

We enable this by enabling our heat pump to not be controlled by simple heating and cooling modes. Rather, we vary the system function with our so-called “Two Way Chiller” on the waterside. The desired heat energy will be transferred via either cold or warm water to the passenger space, and conversely into the atmosphere outside the bus. Very high COP-values are achieved through the use of an optimal heat exchanger with powerful heating and cooling characteristics coupled with a fully integrated, desire-oriented control of all actuators.

 

We are proud to develop the complex software required for such undertakings ourselves, and to also manufacture the electronic hardware in-house. In the next development stage of 2020, the Borealis heat pump will be optimized:

  • 50 kg lighter
  • 100mm slimmer aerodynamic profile
  • 20 dB quieter
  • 10% improved performance at an even better energy efficiency
  • Natural coolant source with about 1.5kg R290 for a 12m bus
  • Integrated thermal management package featuring waste heat recovery and battery cooling

Component development with testing

We develop and manufacture the core components for heating and air conditioning in-house. This is the only way to ensure that our components and systems meet the special requirements of our heavy-duty customers.

 

With the development and manufacture of components in our direct control, we draw closer to the advantage of implementing modular concepts, with which various market demands such as Economy to Premium models can be properly outfitted. Components, which we do not make ourselves, are developed, validated, and sourced from well-recognized and experienced partners.

System development with calculation, simulation and software

The cure for thermal comfort is revealed by organizing the interplay between components in the system in such a way that optimal outcomes in driving mode are reached. To accomplish this, we have invested in the calculation tools for components and simulation tools, which test this interplay across various weather conditions over an entire year. Thermodynamics, fluid mechanics, strength, and acoustics are investigated with models, which simulate the whole vehicle as well throughout a yearly cycle.

 

This way, we accommodate the demand to optimally provide thermal comfort throughout the entire vehicle.

Application technologies with field tests

Our application technologies, including test chambers, in all of our locations achieve the target of pinpointing specific vehicle packaging, and that we meet the desired functionality. Here, we work in close collaboration with our customers as strategic development partners.

 

Foundational for all this is our product development process (PDP), which draws upon our many years of experience, including best practices, benchmarks, lessons-learned to achieve exactly what customers expect.