Battery Know-How

As a partner for battery systems, we support our customers with comprehensive know-how and sophisticated products and solutions. From concept consulting to customized component development and creation of initial prototypes to series production readiness, we support you flexibly and at high speed.

We advise and develop in all core areas of battery technology, esp. in BMS, functional safety or the required standards and certifications. Topics such as field service or data analytics are also part of our constantly growing portfolio.

We would be happy to contribute our know-how, gathered over many years, to your battery project!

Battery development

As battery experts, we support our customers along the entire battery life cycle. From concept creation to initial prototyping and industrialization to series delivery and field service. We even assist our customers with recycling and develop disposal or second life concepts.

Battery system development on your behalf starts with the product idea and, depending on requirements, includes full-scale hardware & software development, prototype production, industrialization, testing and certification through to series launch.

In doing so, we benefit from our deep value creation in development. As a BMS specialist, we develop all the hardware and software of the battery system ourselves. In this way, we achieve the greatest possible flexibility, e.g. in form factors of the assemblies, electrical designs and software functions. Our manufacturer-independent module approach also gives our customers the flexibility to use an exactly matching cell or module for their application from a selection of different suppliers.

Our battery developments always focus on the greatest possible modularity. This means that we are always able to develop a cost-effective and outstandingly suitable product, even for small series and test setups.

Within the scope of our project work, we cooperate closely with our customers. Our dedicated project team is led by our specialized technical project managers. Throughout the entire project, we think first and foremost about the customer’s application and are thus a thinking partner in system development – with a clear focus on an optimal battery!

  • Concept creation battery system and module selection
  • Requirements development and requirements management in the project (with Siemens POLARION)
  • Component and software development along the V-Modell
  • Prototyping and functional demonstrators (Only 4-10 weeks lead time).
  • Industrialization of battery systems
  • Support series start-up
  • Validation of modules, simulation
  • Housing and cable harness development
  • Testing and validation (e.g. EMC testing, performance testing, fatigue testing, FEM modeling)
  • Consulting and validation of functional safety according to ISO 26262, ISO 13849, etc.
  • Documentation for approvals and inspections (TÜV, CertX, Intertek,..)
  • System integration in the powertrain
  • Development and setup of end-of-line testers and production systems
  • Field support & (pre-)series service
  • Telemetry Connection & Data Analytics
  • … and much more!

Functional mock-up (6 weeks)

Operational prototype (12 weeks)

BMS & Component Development

As a contract developer, we develop individual battery electronics assemblies according to our customers’ specifications. All electronic components of the battery system are developed in-house and produced with strong partners for prototypes and series products.

Our work includes hardware development and software development. Strong focus of our work is on BMS development according to the highest standards of ISO26262. But we can also develop components such as the S-Box or the insulation monitor specifically for our customers.

Based on our Futavis technology platform, we continue to develop our circuits and our software kit with our customers. We support the entire process from requirements definition, prototyping, software development, system integration to series ramp-up with test protocols and FCT connections. We also offer our customers certification of our developments along the required standards from a single source.

All data of our work are available to our customers for further use after successful project work.

  • Concept development and consulting regarding application, standards and functional safety
  • Creation of specifications from customer requirements, FuSa requirements
  • Requirements Management and Process Controlling in Siemens POLARION
  • Component development along the V-model
  • Hardware development (Altium, etc.)
  • Software development (C#, Gitlab, etc.)
  • SiL, HiL, BiL testing
  • Performing external tests such as EMC tests, strength analysis, durability tests, etc.
  • … and much more!

Functional safety

With the large number of control units in today’s applications, the functional safety of electronic systems plays a significant role. Functional safety means freedom from unacceptable risk that can arise from hazards caused by malfunctions of electrical or electronic systems. For many industries, guidelines and safety standards exist that contain specifications regarding the individual processes and the technical realization of functional safety.

Our solutions

FuSa Support

We offer combined knowledge and experience from a wide range of application areas for the realization of functional safety in processes and technology in accordance with the applicable laws and standards. We offer:

  1. Security consulting – from concept to prototype
  2. Safety development – tailored to your requirements
  3. Safety assessment – with expertise in technology and processes

Methods for (A)SIL and performance level classification:

  • Risk graph
  • Hazard assessment and risk analysis

Methods for the analysis of systematic errors:

  • Failure Mode and Effect Analysis (Design FMEA (DFMEA) & Software FMEA (SFMEA))
  • Failure Detection Based Design Modification (DRBFM)
  • Fault-based system response analysis (FSR)
  • Common Cause Analysis (CCA)

Methods for random error analysis:

  • Failure Mode, Effect and Diagnostic Analysis (FMEDA)
  • Fault Tree Analysis (FTA)
  • Worst Case Circuit Analysis (WCCA)

For tracking the development process, we use the widely used POLARION tool and specially developed templates based on an extension from the manufacturer. Our template supports, for example, the complete ISO 26262 path from item definition, hazard analysis and risk assessment through functional and technical safety requirements to the requirement specification.

  1. Item Definition
  2. Hazard Analysis and Risk Assessment
  3. Safety Goals
  4. Functional Safety Requirements
  5. Technical Safety Requirements
  6. Requirement Specification
Coverage of risks through Safety Goals
Documentation: Functional safety

Several tools are used for code analysis and testing. From simple code analysis to test specifications, Futavis has acquired know-how to ensure functional safety also at software level. Exemplary we possess experience regarding:

  • MISRA-C Conformity
  • Static code analysis: out of bounds pointer, division by 0, null pointer, etc.
  • Unit testing according to the classification tree method and automated execution and generation of test reports