Mobility Solutions

DINA research project successfully completed Consortium researches first integrated diagnostic system for electromobility Standards drawn up for diagnosis and repair

  • Faster and lower-cost repairs for electric vehicles
  • New measuring methods pinpoint defects
  • Design suggestions drawn up for future battery systems
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  • December 22, 2015
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press release

A competitive maintenance concept for after-sales service is an important factor for the success of electric vehicles. It has to be possible to reliably and safely inspect, service, and repair electric vehicles’ high-voltage systems. A consortium led by the Bosch Group has developed a standardized integrated diagnostic system that in the future will be able to clearly identify and locate defects in the electrical powertrain. The consortium’s project on diagnosis and repairs for electric vehicles, dubbed DINA, was funded to the tune of 2.8 million euros by Germany’s Federal Ministry of Education and Research as part of the leading-edge “Electric Mobility South-West” cluster. The results of this research have important implications for suppliers, automakers, workshops, and testing organizations. Besides the Bosch Group, the consortium included DEKRA Automobil GmbH, the Fraunhofer Ernst-Mach-Institut, and the Research Institute of Automotive Engineering and Vehicle Engines Stuttgart (FKFS).

Any company looking to succeed in the electric vehicle market needs a competitive aftersales concept. For this reason, from July 2012 to July 2015, part of the DINA project was devoted to drawing up standards for the diagnosis and repair of high-voltage systems in electric vehicles and to researching suitable measurement methods. Consortium members also created an integrated diagnostic system to help detect and localize problems in an electric vehicle’s powertrain, from the high-voltage battery and inverter to the motors and charging system. This allows workshops to carry out “modularized repairs”. If it is possible to precisely determine where problems lie, there is no need to replace whole systems. Instead, in the future it will be possible to pinpoint and replace defective parts individually. This makes repairs not only faster, but also much more affordable.

Being able to precisely locate problems is especially important when dealing with high-voltage batteries that consist of numerous independent cells. To make future battery systems easier to repair, the study also makes specific suggestions for how to build them. The diagnostic and repair methods the consortium has developed can now be contributed to the automotive industry’s development projects.

Aftersales needs better diagnostic systems
A look at aftersales reveals how critical the DINA project’s research is. For example, flawless powertrain testing and diagnostics are an indispensable part of technical tests such as general vehicle inspections. What’s more, an electric vehicle’s value depends heavily on its condition, age, and the state of health of the valuable high-voltage battery. The project produced key insights into how to determine this state of health. Similarly, electrical powertrains call for new measuring devices and equipment for workshops and test benches. This is also an area the study addresses with recommendations and approaches for development work.

Leading-edge “Electric Mobility South-West” cluster
With some 100 players from science and industry, the leading-edge “Electric Mobility South-West” cluster is one of the most important regional associations in the field of electromobility. Coordinated by the regional agency e-mobil BW GmbH, the cluster aims to drive forward the industrial-scale manufacture of e-mobility in Germany and to establish the German state of Baden-Württemberg as one of the major providers of electromobility solutions. It brings together leading corporations and SMEs, especially those in the region covering Karlsruhe, Mannheim, Stuttgart, and Ulm, and networks them with local research institutions in four fields of innovation: vehicles, energy, information and communication technology, and production. In addition, the cluster features specialized working groups to ensure full coverage of all topics. The “intelligent move” working group, for instance, focuses on digitalization and automated driving.

Further information
Leading-edge cluster competition: www.hightech-strategie.de
Leading-edge “Electric Mobility South-West” cluster: www.emobil-sw.de

Contact person for press inquiries: Stephan Kraus, +49 711 811-6286

Robert Bosch GmbH:
The Bosch Group is a leading global supplier of technology and services. It employs roughly 360,000 associates worldwide (as per April 1, 2015). The company generated sales of 49 billion euros in 2014.* Its operations are divided into four business sectors: Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology. The Bosch Group comprises Robert Bosch GmbH and its roughly 440 subsidiary and regional companies in some 60 countries. Including its sales and service partners, Bosch is represented in roughly 150 countries. This worldwide development, manufacturing, and sales network is the foundation for further growth. In 2014, Bosch applied for some 4,600 patents worldwide. The Bosch Group’s strategic objective is to create solutions for a connected life. Bosch improves quality of life worldwide with products and services that are innovative and spark enthusiasm. In short, Bosch creates technology that is “Invented for life.”

Additional information is available online at www.bosch.com

Research Institute of Automotive Engineering and Vehicle Engines Stuttgart(FKFS):
The FKFS is an independent institute and provides research and development services for the international automotive industry. For this purpose, it operates various highly specialized test facilities and test vehicles, including several wind tunnels, Europe's largest driving simulator at a research institution, a power train test bench for hybrid and conventional vehicles as well as numerous engine test stands. Self-developed measuring and testing procedures enable the institute to solve complex and challenging problems. Many years of experience in the development and application of simulation tools supplement the range of services. About 150 highly qualified and dedicated employees perform research and development projects in the areas of automotive power trains, automotive engineering, mechatronics and electromobility. The foundation, established in 1930, cooperates closely with the Institute for Combustion Engines and Automotive Engineering at the University of Stuttgart.

Additional information is available online at www.fkfs.de

DEKRA Automobil GmbH:
DEKRA has been active in the field of safety for 90 years. Founded in 1925 in Berlin as Deutscher Kraftfahrzeug-Überwachungs-Verein e.V., it is today one of the world’s leading expert organizations. DEKRA SE is a subsidiary of DEKRA e.V. and manages the Group’s operating business. In 2015, DEKRA will generate sales totalling approximately 2.7 billion Euros. The company currently employs more than 37,000 people in more than 50 countries on all five continents. With qualified and independent expert services, they work for safety on the road, at work and at home. These services range from vehicle inspection and expert appraisals to claims services, industrial and building inspections, safety consultancy, testing and certification of products and systems, as well as training courses and temporary work. The vision for the company’s 100th birthday in 2025 is that DEKRA will be the global partner for a safe world.

Additional information is available online at www.dekra.de

Fraunhofer Institute for High-Speed Dynamics, Ernst-Mach-Institut, EMI:
The Ernst-Mach-Institut studies high-speed processes in experiment and simulation. We consider them from a physical and engineering perspective and develop solutions for industrial applications. Our center of interest is on security, resilience, reliability, efficiency and sustainability of structures, components and systems under dynamic and extraordinary loads. We analyze phenomena of crash, impact and shock-waves in materials, microstructures as well as in complex systems. Our applications range from components and design of structures to whole vehicles and defense technology systems, from buildings and infrastructures, urban systems and networks to satellite systems.

Additional information is available online at www.emi.fraunhofer.de

PI9112 - December 22, 2015

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