Engineering a Clean Energy Future
Since 2010, our team has helped top industry firms push the boundaries of technology and performance in electric and hybrid-electric vehicles. We develop systems for our clients’ most demanding applications and environments, using our existing products or creating new ones:
Electric aircraft
Battery management systems and vehicle control unitsWorld championship-winning electric motorcycle
Electrical systemsFastest street-legal electric car in the world
Vehicle control units and electrical systemsFirst electric off-road vehicle prototype from a major OEM
Electrical systemsElectric vehicle race program for a major OEM
Battery management systemElectric underground mining vehicle
Vehicle control unit
Case Studies
High Voltage Applications
MINING VEHICLECHALLENGE: Exposure to extremely challenging and corrosive conditions & long duty cycle (20-22 hours per day)
SOLUTION: An active cell balancing architecture enabling continuous cell balancing as needed
A major challenge for this project was long-term cell-to-cell balance. Without long rest periods to perform balancing, traditional passive balancing techniques were insufficient.
ALL-ELECTRIC SUPERCAR CHALLENGE: Distributed battery pack consisting of various sub-packs connected in series
SOLUTION: Control system and BMS
The vehicle architecture presented a number of challenges with a distributed pre-charge which were overcome with innovative hardware and software techniques.
As the world's fastest street-legal electric car, its powertrain includes two motor cores and inverters operating at 800V and capable of a maximum power output of 550kW.
SOLAR-POWERED ELECTRIC AIRCRAFTCHALLENGE: Weight and redundancy tradeoffs unique to aircraft applications
SOLUTION: With partner companies, the design of the battery, BMS, charge control system and hybrid control system
After months of ground testing, a number of aerial maneuvers tested the aerodynamic design and powertrain.
ELECTRIC SEMI-TRUCKCHALLENGE: Safely balancing power flow between inverters, auxiliary power sources and systems with up to 1 MW traction power
SOLUTION: Consulting on the powertrain design, control strategy and battery management system
As part of a large vehicle development program, Stafl Systems provided consulting for a large Class 8 semi-truck project. The design included a 300 kWh 800V liquid-cooled battery system that drove 6 drive inverters.
Low Voltage Applications
ELECTRIC SURFBOARDCHALLENGE: Reliability in a seawater environment and under variable weight load
SOLUTION: Battery management system
The 48V high-power battery provides one hour of run time in variable load conditions.
INNOVATIVE ELECTRONIC CONSUMER PRODUCT We played a pivotal role in the development of an innovative battery-powered consumer product launched in 2021. Combining unique power control and battery management, we applied our technology to a small hand-held product.
Stationary Storage
STATIONARY ESS FOR DEMAND-RESPONSECHALLENGE: Improve an existing BMS design exhibiting flaws in the field
SOLUTION: Design changes increasing reliability and accuracy of calculated battery values (SOC, SOH and SOE)
Our team performed rigorous tests on the existing design and discovered many design deficiencies and flaws in both the hardware and software. Some of these issues even led to bricked battery packs and expensive truck-rolls for field service.
BATTERY-BACKED ELECTRIC VEHICLE FAST CHARGER We are developing the power flow control system and BMS for a battery-backed electric vehicle fast charging system. This unique system combines battery-backup, AC grid interaction and solar integration.
CAREERS AT STAFL SYSTEMS
Are you interested in joining a culture by engineers, for engineers? At Stafl Systems we empower our team members to get creative and be directly involved in making impactful decisions.
