Podium Engineering has a short but brilliant history. Born in the firm belief that design quality, high project commitment and absolute respect of deadlines are key competitive factors for a consulting and engineering company, Podium has soon held a strong position in the market. A young and dynamic company grown in the Turin's automotive and motorsport background merging together multi-disciplinary skills and competences coming both from research and industry environment. Complete racing cars, vehicle prototypes, high-performance hybrid powertrain, mechatronics systems … our engineering team, has been successfully involved in many projects and today we are proud to offer our services in motorsport application, high performance electric powertrain and general engineering services.

Podium Engineering has a set of design tools developed to manage the preliminary steps of the design process in order to:

• ensure vehicle feasibility • target the subsystems performance • schedule the whole project

Our team of proven motorsport engineers can manage 3D Modeling, vehicle dynamics, aerodynamics, structural analysis, electronic controls and wiring with a concrete and multidisciplinary approach optimized to reduce our time to market and to save costs.

Concept design

Chassis and powertrain concept development

Innovative solution to match customer requirements

Detailed Design

Vehicle Dynamics and elasto-kinematics analysis

CAD design

FEM analysis and optimisations

Prototype &Validation

Workshop management

Test Bench analysis and validation

Electronics: Wiring Harness design and development.

Drafting of electric diagrams and bill of materials documentation.

Integration testing and system performance development.

Wireless system design.

Controls and Software development: Control strategies definition and model based design within Matlab/Simulink environment.

Automatic code generation using Matlab/Simulink models by means of embedded coder.

Use of Rapid Control Prototyping and Hardware-In-the-Loop (HIL) technologies.

Use of communication protocols such as CAN, LIN, Ethernet, RS232, RFID.

Use of data acquisition systems for analysis and characterization of embedded devices.

Vehicle Technology Expertise

Podium engineering customer list includes racing and road car manufacturers, motorsport team and institutional customers. We are now working as mechanical and electronics designers in many different motorsport programs: complete vehicle for GT endurance races, development kit for touring cars and race engineering for GT and Touring cars. In the last few years we have been involved in the development of many different suspension systems, 2 complete aerodynamic kits for Gt cars, 5 complete wiring and electronics system for race cars, 3 high power battery pack for KERS application and many other automotive applications.

Podium Powertrains is the recently established Podium Engineering business unit. A dedicated research and development Lab-center in Aosta hosts the development of advanced technologies to improve consulting activities and to create a product range ready for the market.

Podium designs and manufactures batteries for a wide range of applications, from low-power batteries for industrial uses, to high-power high-capacity batteries for use in demanding automotive applications such as high performance hybrid vehicles. Having designed and delivered a world-leading performance hybrid battery system, we have a proven track record of designing, developing and manufacturing complex battery system solutions for demanding applications whilst optimising performance, cost, weight and life. We follow full vehicle integration processes, including system/electronic interface.

• Cells – Podium Engineering is an independent provider of battery design, development and supply for demanding

automotive applications. – Podium Engineering acts as a system integrator between customers and cell suppliers to provide customers

with battery solutions tailored to their specific needs. We take particular care over cell specification and selection, to ensure that the appropriate cells are chosen for the desired customer application.

– Application performance is dictated by the battery materials chemistry, the cell technology and the integration engineering into the end application battery pack.

• Electronics – Podium Engineering offers a range of Battery Management Systems (BMS) depending on the application.

• Lightweighting – Podium Engineering delivers innovative solutions for smaller and lighter batteries, while maintaining the

safety

• Power management – Control and management systems are designed to provide performance over life of vehicle/system

• Simulation – Electro-thermal Modelling and Simulation of Li-ion cells aids pack design, thermal management assessment

and validation – CFD Simulation is used to analyze cooling systems for high performance hybrid pack – Performance evaluation / validation against real drive profiles (e.g. Nordschleife)

• Safety – Strong safety capability is built into our battery systems through electrochemistry, cells, controls, electronics,

mechanical and systems design.

Where parameters A, B, K, Qnom will be identified with the presented procedure by means of the experimental data.

Additional non-linearities were added to represent the effects of the SOC, current and temperature on the battery resistance variation (different in charge and discharge) and the current loss in charge.

Electric cell/battery model identified and characterized with testing

INPUT

Experimental Discharge Curves

Enviromental properties

OUTPUT

State of Charge

Instant Power (I - V)

Battery Temperature

Heat Exchanged

Cell electric model identified and characterized with testing

Lithium cell temperature estimation and heat exchange split

• CDF analysis are adopted to design the cooling system required according to the mission profile of the battery

• Air/Liquid cooling could be simulated in order to optimise battery pack overall performances

• Charge and Discharge simulations to estimate transient cell temperatures

• Conduction and convection heat transfer analysis

KEY SPECIFICATION BATTERY TEST BENCH

Max Discharge Power 14.4 kW

Max Discharge Current 600 A

Max Charge Power 10 kW

Max Charge Current 340 A

Voltage Range 3 ÷ 160 V

Monitored Parameters Cells Temperature Cells Voltage Cells Current

Controlled Parameters Current Voltage

Time Air Temperature

Cycle Profile

Safety Features Temperature Control HV Contactors

Smoke Detectors*

Environmental Simulation Chamber

dSPACE MicroAutoBox

EA Power Supply 10kW

EA Electronic Load 14.4kW

CA

N

CA

N

Cells / Modules

CAN & Analog Data Logging

DC

LIN

E

Our own designed BMS is currently under the development/test phase.

– Master – Slave Configuration

– CAN bus up to 1Mbit

– Temperature Monitoring

– Cells Balancing

– Insulation monitor GFD

– Contactors / relays control

– Over/Under Voltage

– SOC – SOH Estimation

– Current Measurement

Traction Battery Pack

Vehicles Applications

Hybrid Powertrain

3 High voltage/high power hybrid battery pack 4 High capacity, full electric vehicle battery pack

1 Race car 1 Supercar 2 Design prototypes 1 R&D car 1 Public transportation vehicle Many feasibility studies (Full electric single-

seater, passenger cars, off-road vehicles…)

1 Motorsport hybrid system (KERS) 1 Supercar system 2 Electric prototype system

Podium Engineering S.r.l. Sede Legale | Fr. Champagne 3A | 11020 Verrayes (AO), Italy

Sede Operativa | Via Lavoratori Vittime del Col du Mont 24 | 11100 Aosta, Italy

info@podiumengineering.com

www.podiumengineering.com

Tel: (+39) 0166690983

Fax: (+39) 0166685170

Ing. Francesco Monti Francesco.monti@podiumengineering.com

Mobile: (+39) 3288250873