hybird-electric-fuel-cell-dev

Hybrid/Electric/Fuel Cell

MGA Research Corporation is your source for Hybrid/Electric/Fuel Cell Vehicle Development. We are the leading independent organization with internal teams specializing in the development of hybrid batteries, fuel cells and vehicles.

Experience

We provide a multitude of services to the hybrid/electric/fuel cell vehicle market from component level (battery packs, mounting, wiring harness) to full vehicle level (crashworthiness, durability, brake testing). With over 25 years of battery testing experience, we are in a unique position to serve the hybrid/electric battery industry with issues including quality assurance and regulatory approval.

Evaluations are performed over a wide variety of conditions including governmental and industry standard testing. Examples are:

  1. U.S. Advanced Battery Consortium (USABC) Freedom Car  and related test manuals
  2. Society of Automotive Engineers (SAE) J2464 “Guidelines for Electric Vehicle Safety”
  3. UN ST/SG/AC.10/11 Recommendations on the Transport of Dangerous Goods Manual of Tests and Criteria
  4. GMW 3172 “General Specification for Electrical/Electronic Component Analytical/Development/Validation (A/D/V) Procedures for Conformance to Vehicle Environmental, Reliability, and Performance Requirements”.
Facilities

In response to industry needs, we have constructed a specialized Battery Center to help facilitate the unique types of product tests that are carried out on component level battery units. This facility includes “test cells” that were designed and built by our own Fabrication Center to provide a “bunker” type of environment where the various evaluations are performed. Sometimes tests of prototype parts can produce hazardous results such as venting of gases and/or fires and these cells have been built to withstand these types of occurrences in a safe manner.

In addition, we operate various facilities for the full scale evaluation of hybrid vehicles including governmental standards and product life/durability evaluations. Crashworthiness evaluations include all types of standard modes (front, side, rear impacts) and we have been awarded a five year contract (2006 to 2011) from the National Highway Traffic Safety Administration (NHTSA) for performing testing to FMVSS 305: Electric Vehicles.

With major facilities located near Detroit, the R&D center of the automotive industry, we are well positioned to assist in the development of hybrid technologies. These are just a few of the reasons why OEMs and suppliers throughout the world seek out our services.

Engineering Support
  • Evaluation Criteria
  • Design Review
  • Validation Planning
  • Benchmarking
Federal Motor Vehicle Safety Standard (FMVSS) 305: Electric Vehicles

Application:

  • Passenger cars, MPV/s, trucks, buses with GVWR 4,536kg
  • Propulsion power uses 48 nominal volts of electricity or greater
  • Vehicle speed is greater than 40 kph (attainable in 1.6 km on paved surface)

Test Modes:

  • Frontal Crash-up to 48 kph including oblique angle
  • Side Crash-up to 54 kph (FMVSS 214)
  • Rear crash-up to 48 kph
  • Optional-80 kph, 70% overlay

Requirements:

  • Limitation of electrolyte spillage
  • Retention of propulsion batteries
  • Electrical isolation of chassis
Full Vehicle Evaluations
  • On-Road and Proving Ground Data Collection
  • Data Analysis
  • Vibration/Fatigue/Component Durability
  • Vehicle Durability
  • Chassis-battery mounting
  • Powertrain/Drivetrain-propulsion system
  • New product shakedown
  • Airbag & Sensor Development
  • Sensor and system algorithm/calibration evaluations
  • Brake evaluations
  • FMVSS 135-Light Vehicle Brake Systems
Facilities and Equipment
  • Facilities and equipment designed by experienced design and test engineers
  • Turn-key facilities
  • Protective test cells
  • Customized fixtures
  • Complete manufacturing center including:
    • Mechanical
    • Electrical
    • Software
    • Training and Checkout
Mechanical/Electrical Abuse
  • Crush
  • Penetration
  • Immersion
  • Shock
  • Vibration
  • Impact
  • Acceleration
  • Connector Strength
  • Short Circuit
  • Overcharge
  • Forced Discharge
  • Functional Evaluation
Environmental/Durability
  • Thermal Cycling (Hot/Cold)
  • Thermal Runaway
  • Thermal Shock
  • Extreme Heat
  • High Frequency Vibration
  • Multi Axis Simulation Table (MAST)
  • Salt Spray
  • Dust
  • Rain Simulation
  • Altitude (Vacuum)