WiredWhite Engineering Services

Empowering Your Success: Expert Engineering Services to Keep You Leading the Market

WiredWhite GmbH is a reliable full-cycle engineering services provider who specializes on helping companies in the e-mobility, renewables and other sustainable industries to drive their product development success with high quality standards, expertise and great value for money.

Intro Team WiredWhite

Our Full-Cycle Engineering Services

System engineering

Electrical drive and high voltage component engineering​
Design, development, validation and test

E-Machine Design

Electromagnetical design​
Insulation system design​
Mechanical strength calculation​
Thermal modelling
Cooling system design

SW-Development acc. to v-Process

Requirements engineering​
Application software (model-based development)​
SW functions detailed design​
SW architecture​
Drive control
Thermal modelling
Derating functions
SW unit test​
SW release test

Project management

Technical leading​
RFI, RFQ & QnQ support​
Technical project review​
Scrum
Kanban
Agile
Kaizen Lean
V-model

15+ Years of Industry Expertise: WiredWhite at a Glance

Our Background

Our team, composed of PhD holders with extensive academic backgrounds, is internationally recognized for advancing the fields of electric machine design, system modeling, software development, and testing. With multiple IEEE publications, we have presented our work at prestigious conferences worldwide, including ITEC, ICEMS, ECCE Asia, SPEEDAM, EVS KINTEX, and many others.

We actively contribute to global electrification projects, collaborating closely with multidisciplinary teams across Europe, America, and Asia, driving innovation and fostering international cooperation in the electrification domain.

#OurBackground #IEEE #ScientificPaper #InternationalExperience #CompanyAtAGlance #SuccessStory

Aerospace

We bring extensive experience working with a major global aerospace company at its advanced aviation site in Garching, specializing in hybrid-electric applications. Our work adhered to the environmental conditions and test procedures for airborne equipment, ensuring compliance with industry requirements for the environmental testing of avionics hardware.

We have contributed to the development of propulsion systems in several German and European hybrid-electric aviation programs, supporting the transition from aircraft with conventional gas turbines to hybrid-electric propulsion systems powered by fuel cells and stabilized by high-voltage (HV) batteries. As component and product owners for electrical drives within the project team, we played a key role in developing flight-altitude-ready, flight-worthy electric machines, power converters, and drive control software.

Additionally, we were involved in aviation projects focused on fully electrically driven aircraft, contributing to system engineering and requirements engineering for battery packs and their sub-components, such as solid-state power controllers and battery power distribution cards. Our efforts supported one of the leading eVTOL unicorn startups based in Oberpfaffenhofen, helping it achieve significant milestones toward a successful piloted flight campaign.

#Aerospace #Aviation #RTCA #DO160 #DO178c #eVTOL #HybridElectric #FuelCells #1MW #800VDC #SSPC #BPDC

Automotive

Our team contributed to major projects for the two largest German car brands and OEMs, focusing on platform technologies for battery electric vehicles. This included developing application software functions for eDrive systems and designing permanent magnet synchronous machines (PMSM) with both internal and surface-mounted rotor structures.

The final product, developed in compliance with functional safety for road vehicles, adhered to ASPICE (Automotive Software Process Improvement and Capability Determination) and ASIL (Automotive Safety Integrity Level) standards. It has been successfully brought to market, meeting the highest industry requirements for safety and reliability.

#Automotive #eDrive #eSystem #PMSM #IPM #ISO26262 #ASPICE #ASIL #LabVIEW #CANape #INCA #48VDC #400VDC

Electric machine & inverter

We support automotive and electromobility projects with our expertise in the development of electric machines and drives for applications in electric and hybrid-electric vehicles with onboard networks ranging from 48VDC to 400VDC.

Our contributions include developing thermal models for eDrives using the MATLAB Simulink environment, performing software requirements engineering in Polarion, and conducting FEM analysis with Maxwell and Motor-CAD to optimize the performance of permanent magnet synchronous machines (PMSMs).

We rely on experience from multiple global collaborations in the automotive, aerospace, and rolling stock sectors. This includes projects with the world’s largest motor developer, headquartered in Japan, for a France-based global OEM, the development of locomotive systems in collaboration with the world’s second-largest rolling stock manufacturer from France, and contributions to electrification programs in aerospace, supporting the largest American aircraft engine supplier, headquartered in the US.

#eMotor #IPM #PMSM #PermanentMagnetSynchronousMotor #FEM #FEA #Ansys #Maxwell #MotorCAD

Software

We contributed to model-based software development for drive control algorithms, including field-oriented control (FOC) for IPM machines. Our work involved modeling electric machine losses—copper losses (DC and AC), stator and rotor iron losses, friction losses, and magnet losses—and enhancing torque accuracy in torque control algorithms.

Additionally, we developed eDrive derating functions such as stator and rotor thermal derating based on temperature signals or estimations, I²t derating, voltage derating, and more. These functions were designed to prevent system shutdowns, eDrive component failures, or the loss of the entire traction drive system.

Moreover, we performed thermal modeling of the electric machine and power converter, leveraging loss calculations and energy equations to ensure system reliability and performance.

#Software #MBSE #FOC #ModelBased #DRCO #400VDC #200kW #BEV #EQB #ID #Matlab #Simulink #TargetLink #dSPACE

Systems Engineering & Project Management

Our team has solid expertise in the development of electrical systems, including electric motors, converters, EV chargers, and charging station solutions. We have worked on simulation models that describe energy flow between the charger and the vehicle’s power network, enabling optimized energy management and performance. Additionally, we have contributed to creating interface control documents (ICDs) for the charging system and the overall power system of a vehicle, ensuring smooth integration and reliable operation across all components.

Whether it’s electric machine development, embedded software development, or system engineering, our team is ready to support you in tackling complex challenges and advancing your product to testing, prototyping, and detailed design freeze stages. We can begin our collaboration at the Request for Information (RFI) stage or seamlessly integrate into your current project phase, ensuring smooth progress while adhering to industry best practices in project management. Our expertise extends to guiding the final, safe product through certification and successfully bringing it “to the streets.”

#Systems #ProjectManagement #SiemensPolarion #REQ #ICD #RollingStock #DCDC #ACDC #PDU #Inverter #Controller #EmbeddedSystems #eMobility #EV #PHEV #Charging

Why WiredWhite is the Perfect Engineering Partner for You

More than 15 years of industry experience.

Skillful users of various engineering tools including MATLAB, Simulink, Ansys, CAD, etc.

Network of 600+ professionals from engineering domains.

Integrated Project Management System for maximum efficiency and transparency of our work.

Simulink Model for the Analysis and Development of Power Networks in Hybrid Electric Vehicles

#UseCase #SoftwareDevelopment

Task

Develop a model that includes the most significant components of a low-voltage electrical network, such as an alternator, rectifier, loads, and battery, structured as sub-models. The power network model should be designed in a way that allows individual sub-models to be adjusted or entirely replaced, following a modular approach.

Our work

Based on customer requirements, the given current-excited multiphase synchronous machine model was created and parametrized. The model-based software development team at WiredWhite also handled the tuning of the excitation current PI controller. For the modeling of power electronics, multiple options—such as Simscape, SimPowerSystems, and Plecs—were considered and thoroughly evaluated.

In this model, the WiredWhite team has examined the modeling of each individual component, such as the sub-model of the alternator and the sub-model of the excitation current control, as well as the functional principles of the vehicle’s power network. This was done while running simulations of automotive-specific test cases and driving cycles.

Finally, the model and the control loop were verified by comparing the simulation results with the measurement results from a test bench.

Results

The typical use case of engine start-up (mimicked by a DC electric machine) and the impact of the low-voltage generator on the vehicle’s power network and voltage stability were analyzed. Our team modeled a detailed speed profile of the real drivetrain and captured the excitation and load currents, actual voltages, and generator usage. Through laboratory experiments, the team was able to verify the accuracy of the developed model.

Conclusion

This is just one example of a model-based software development project. Our team can provide you with a tailor-made solution for software development in automotive applications.

We Are Supporting Businesses, Executives, and Innovators Worldwide

Freelance Agencies

Teams of Engineers

Start-ups

Companies

Electric Machine Design of a Claw-Pole Alternator

#UseCase #HardwareDevelopment

Task

Create an electric machine design for a claw-pole alternator with a delta-connected six-phase stator winding, a rotor winding with current control, and two passive rectifiers.

Our work

The model had to be co-simulated with the model of the power electronics.

The relatively high nominal and maximum speed of the application makes the FEM simulation more complex and requires consideration and subsequent analysis of proximity and skin effects in the stator winding of the machine. 

The rotor design includes magnets between the claws to compensate for the leakage flux of the claws and to enhance the main flux originated by the winding.

Results

Based on the created 3D FEM co-model, the behavior of the automotive six-phase claw-pole alternator and power electronics in the vehicle power network has been investigated. In addition to the FEA, MATLAB Simulink models of power electronics, the electrical machine, and other power network components have been parametrized to provide a detailed analysis of the vehicle power network.

Conclusion

With regards to e-machines, besides the electromagnetic design, our team can also support you with insulation system design, mechanical strength analysis and calculation, thermal modeling, and cooling system design.

Proficient ANSYS License Holders

ANSYS LOGO

MathWorks Start-Up Program Approved Member

MathWorks Logo

Proficient MATLAB & Simulink License Holders

MATLAB LOGO

ANSYS is a registered trademark of ANSYS, Inc.; MATLAB/Simulink is a registered trademark of The MathWorks, Inc. All product names mentioned on www.wiredwhite.com are trademarks or registered trademarks of their respective owners.

Company Milestones

July 2023

The 4 founders have set the ground and officially founded WiredWhite GmbH in Munich, Bavaria, Germany. 

September 2023

The number of engineering and IT experts on the platform is around 150. The number of customers 30.

May 2024

The number of engineering and IT experts has grown to 450+ members. The number of customers has grown to 80.

October 2024

Won the Global Business Award 2024 in the category of Best eLearning & Full Cycle Engineering Services 2024 – Europe 🏆

November 2024

Featured in renowned publications, including Associated Press News 📰

December 2024

The team of engineering and IT experts has expanded to over 650 members.

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Let's Get Started Together

Contact our team and talk to one of our engineering experts to get an insight about the competences of our team and to start working on your project.

Committed to Excellent Quality & Sustainability

Sources:
https://www.deutschebahn.com/resource/blob/12718362/f88b113d9e339af17e497b5ea80941e0/ALHB-654_12-2020-data.pdf

Trademark Disclaimer: all trademarks, logos and brand names mentioned on www.wiredwhite.com are the property of their respective owners. All company, product and service names used in this website are for identification purposes only.

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