Electrification Project Process
Structured development processes are the foundation of successful electric vehicle and system developments. We accompany OEMs, machine manufacturers, and industrial companies from the initial concept idea to series integration. We rely on clear phases, interdisciplinary engineering, and transparent approval processes.
Holistic
Holistic development of electric vehicle and high-voltage systems
Structured
Structured project processes with clear milestones and approvals
Interdisciplinary
Interdisciplinary engineering across mechanical, electrical, and software domains
Goal-Oriented
Focus on project security, functionality, and production readiness
Structured Development of Complex Vehicle Systems
Structured Development of Complex Vehicle Systems The development of electric commercial vehicles, special-purpose vehicles, and off-highway systems requires clear processes and workflows. High-voltage architectures, power electronics, software, thermodynamics, and mechanical integration must be precisely coordinated across all project phases.
That is why we follow clear development processes aligned with established OEM and product development methodologies, without sacrificing agility. Clear responsibilities, defined milestones, and transparent approvals create visibility, reduce risks, and ensure technical and economic feasibility.
Our Development Phases
The development process is divided into several key project phases. Each phase includes defined engineering activities, technical reviews, and approval gates.
Preliminary Study System Definition
System Design and Engineering
Prototyping and Integration
Industrialization and Series Production
Preliminary Study System Definition
In the early project phase, requirements, operating conditions, and technical parameters are analyzed. The goal is to define a robust system architecture and identify technical risks and dependencies early on.
Requirements Analysis
Definition of requirements specifications, duty cycles, safety requirements, and regulatory frameworks.
Feasibility Studies
Technical evaluation of architecture variants, technologies, and integration options.
System Concepts
Development of initial vehicle, high-voltage, and system architectures including interface definition.
Project Planning
Definition of development scope, resources, milestones, and validation strategy.
Typical Deliverables
System Design Engineering
Based on the defined architecture, interdisciplinary development of all subsystems takes place. Electrical, mechanical, thermodynamic, and software components are developed in parallel and systematically integrated.
Electrical Development
HV/LV architectures, wiring harnesses, safety concepts, power electronics, and energy distribution.
Mechanical and Thermal Development
CAD design, packaging, cooling concepts, structural design, and installation space integration.
Software Development
ECU software, CAN communication, diagnostic functions, and safety logic.
Systems Engineering
Interface management, FMEA, functional modeling, and verification and test planning.
Project and Quality Management
Across all engineering disciplines, continuous project control is maintained through technical reviews, risk analyses, version management, and defined approval processes.
Development with Clear Milestones
Each development phase is secured through defined approvals and technical reviews. This enables early risk detection, reduces integration issues, and ensures transparent documentation of development status.
Prototyping and System Integration
In the integration phase, hardware, software, and mechanical systems are validated for the first time as a complete system. The goal is technical validation under real operating conditions.
Prototype Construction
Construction of functional prototypes, development vehicles, and integration platforms.
System Integration
Integration of high-voltage, software, cooling, and control systems into the overall platform.
Validation and Testing
Functional tests, thermal validation, safety inspections, and system verification.
Optimization
Analysis, troubleshooting, and iterative refinement of the complete system.
Typical Test Scope
Industrialization and Series Production
After successful validation, SUNCAR supports the transfer of developed systems into production and series operation.
Series Preparation
Optimization of production, assembly, and service processes.
Documentation
Creation of technical documentation, production documents, and service information.
Certification
Support with regulatory requirements, compliance, and approval processes.
Series Support
Support during pilot series, production ramp-up, and technical optimization.
Industrialization Phase Deliverables
Structured Processes Create Project Security
Complex development projects require clear workflows, transparent decisions, and traceable technical approvals. That is why we rely on structured development and project processes throughout the entire product lifecycle.
Through systematic planning, continuous risk and change management, and defined milestones, we create maximum transparency and reduce technical and organizational risks.
Success Stories
References
Selected development projects and system solutions in the areas of electric commercial vehicles, off-highway systems, and special-purpose vehicles.
SUNCAR has received multiple awards
European Solar Prize 2015
European award for pioneering projects in the field of renewable energy and sustainable energy applications.
Watt d’Or
2020
Award from the Federal Office of Energy for outstanding projects in the field of energy efficiency and innovative energy technologies.
eMove360°
Award 2018
International prize for forward-looking solutions in the areas of electromobility, connected driving, and sustainable mobility.
Here for you
Project Inquiry
Would you like to discuss a development project or need support with electric vehicle and system development? Our team is happy to assist you with reliable processes.
SHALL WE GET STARTED?
Start your electrification project – with a process-reliable partner who understands systems
We develop and integrate systems – from the initial idea to implementation in the machine.