A TIER1 supplier, commissioned by a renowned OEM to develop a complete vehicle from the concept phase, including developing electrical harnesses according to the VOBES process and complying with OEM standards (VW6000, VW80000). This required considering the feasibility and optimization of the production process for individual harnesses, their assembly into a complete product, and the potential for installation in a vehicle still in the early stages of development, while also maintaining the required quality, minimizing unit production costs, and ensuring parts were not susceptible to changes in later project stages.

Solution: Endego’s integrated team and advanced simulations

Endego assembled a specialised team to address these challenges. Our approach included:

• Specialized teams: the team developed HV and LV harnesses, ensuring compliance with VW6000 and VW80000 standards and optimizing production costs.
• Project Management: we provided a Project Manager along with a team to manage the project, embracing the ASPICE and VOBES processes.
• Simulations: using IPS, our team conducted thermal and durability simulations, virtual tests, and dynamic harness simulations.
• Cross-department communication: to ensure proper packaging, we managed synchronization with the client’s Body-In-White, Interior, and Exterior departments.
• EMC testing: the concept was checked for EMC compliance to prevent electromagnetic interference.
• Compliance: adhering to the VOBES process and conducting ISO26262 Functional Safety analyses.

Technologies: Leveraging multiple tools

Our solution utilised advanced technologies and methodologies:

• EB Cable and LDorado: For detailed harness design
• CATIA EHI and ELENA: For 3D routing design and integration.
• Teamcenter and Architect: For project management and documentation.
• Functional Safety (FuSa): Incorporating safety principles to meet rigorous standards.
• IPS and ASPICE: For simulations and adherence to process standards.

Expectations and standards for complete car development:

• Stringent compliance: There is an increasing need to adhere to specific standards and processes.
• Advanced simulations: Growing reliance on simulations for design validation and performance testing.
• Cross-department collaboration: Emphasis on seamless communication between different vehicle development departments.
• Functional safety: Incorporating comprehensive safety analyses to meet industry standards.
• Cost efficiency: Focus on maintaining high quality while minimising production costs.

Endego’s competences

Endego’s competences in vehicle harness design and development are extensive. Our capabilities include:

• Process expertise: Assisting clients in implementing specific development processes to streamline project execution.
• Production implementation: Implementing products into production efficiently to ensure seamless integration and high quality.
• Electrical diagrams: Creating electrical diagrams that serve as the blueprint for harness designs.
• Packaging
• 3D models and 2D drawings: Developing 3D models and 2D manufacturing drawings .
• Component design: Designing and optimizing individual components.
• Simulations
• FuSa

For more detailed insights into our competencies, visit our Wiring Harness page.

Endego’s recent project with a TIER1 supplier showcases our ability to meet complex requirements and deliver successful outcomes. By leveraging advanced technologies and our extensive expertise, we ensured the project adhered to stringent standards and was completed on time.

For inquiries or more information about our services, don’t hesitate to get in touch with us.

Endego designed transparent optical parts, integrating complex geometry features like collimators, TIR surfaces, flanges, and mechanical features such as locators and screw bosses. The parts were produced as 2k components with a sealing surface located on the optical surface. Throughout the process, we closely collaborated with the component supplier, ensuring successful tool production and a seamless transition to serial manufacturing. 

Technologies: 

• Injection molding 
• LEDs 
• PCBs 
• Vibration welding 
• Light blades 
• Collimators 
• Smoked materials 

By combining innovative mechanical and optical design with strong collaboration, Endego delivered a ready-for-production rear lamp that met all functional and manufacturing requirements. This project demonstrates our ability to tackle complex design challenges and bring high-performance automotive lighting systems to market. 

For more updates on our projects and solutions, stay tuned to our blog, or contact us for more information. 

Endego provided the following services to ensure the project’s success: 

• Hardware requirements analysis: Conducted a thorough analysis to define key performance parameters and ensure proper component placement, alongside setting routing guidelines. 
• Simulation and testing: Our team ran signal integrity measures, simulations for different LED BIN variants, and CAE simulations for thermal analysis of the panels. We utilized LTspice to conduct analog electronic simulations and performed a worst-case analysis for electronic and electrical (E/E) components. Additionally, we conducted a Serious Short Circuit (SSC) analysis and supported the customer with EMC testing to ensure compliance. 
• Functional Safety analysis (FuSa): We performed an in-depth FuSa analysis of the hardware architecture to guarantee system reliability and safety in alignment with automotive standards. 

The development process was comprehensive, with close attention paid to optimizing component performance and ensuring safety, all while managing cost and time efficiency. 

Technologies 

We utilized advanced technologies such as Altium, LTspice, DOORS, Jazz, TC Team Center, RTC Rational Team Concert, and FuSa to ensure the highest level of design precision and performance in compliance with automotive standards. 

By leveraging our expertise and cutting-edge tools, Endego was able to streamline the development process for the rear lamp systems, delivering a solution that met the client’s expectations for quality, safety, and performance. Our collaborative approach ensured that the client received support throughout the project lifecycle, from concept to completion. 

Stay tuned to our blog for more updates on how Endego continues to deliver advanced solutions across the automotive industry. For inquiries or more information about our services, feel free to contact us. 

The customer needed assistance in implementing and verifying software on a new headlamp hardware (PCB board). The tasks included checking power and temperature conditions, implementing software protections, and ensuring communication between the light module and car ECU. 

Solution: Comprehensive design and verification 

Endego provided a complete solution by designing, verifying, and configuring key hardware and software components. We implemented and tested the following: 

• Boost converter (LM5122): Ensured a stable 36V power supply through hardware design and testing. 
• Programmable current sources (TPS92518): Designed and configured for optimized power management. 
• SPI communication driver: Implemented a driver to manage communication across the system. 
• LED matrix drivers (TPS92664): Designed and configured programmable drivers for matrix control. 
• Gaussian brightness distribution: Implemented across the LED matrix to ensure the desired light beam. 
• CAN FD communication: Verified communication between hardware and software. 
• Dynamic power derating: Implemented protection from overheating through real-time current and temperature management. 
• External cooling fan control: Designed hardware control for an auxiliary cooling system. 

Technologies 

• ASPICE, Embedded C, CAN_FD, SPI, UART, ADC, Boost DC-DC Converters, Programmable Current Sources. 

Endego’s innovative solutions ensured a seamless hardware-software integration by addressing key aspects of the front car lighting system. Through the use of automotive protocols like CAN FD, SPI, and programmable current sources, we optimized both power management and communication between the light module and the car’s ECU. Dynamic testing allowed us to configure thermal protections, such as dynamic power derating, ensuring the system could handle temperature fluctuations. By designing and validating each component, including LED matrix drivers and external cooling controls, we provided robust protection and maintained optimal performance, even under demanding conditions. 

For more insights, stay tuned to our blog or contact us for more information. 

Our customer, OE Industry, aimed to promote their innovative OLED ambient lighting device at job fairs. They needed an electronic prototype that could demonstrate the module’s capabilities effectively. This required not only hardware development but also a sophisticated software solution to control and display various visual elements.

OE Industry – an innovative brand focused on small-series manufacturers, producing from 10 to 1000 vehicles per year, designs, produces and supplies lighting systems for automotive and e-mobility.

The company helps vehicle manufacturers to ensure that their projects gain technological value on the market. It fills a niche among lighting manufacturers and provides smaller companies with safe and innovative solutions.

Solution: Endego’s comprehensive prototype development

Endego delivered a complete solution, providing a hardware prototype integrated with custom software capable of interfacing with the customer’s OLED device. We also developed a Windows program to transfer data to the hardware, enabling the display of signs, words, and emotes.

Key elements of our solution included:

• Hardware prototype: Developing a robust hardware prototype that integrates seamlessly with the customer’s OLED device.
• Custom Software: Creating software to control the OLED device and demonstrate its capabilities effectively.
• Windows program: Developing a user-friendly Windows application to transfer data to the hardware and display various visual elements.

Technologies: Leveraging advanced tools and frameworks

To deliver this solution, we utilized a range of advanced technologies and frameworks:

• C++ and C#: Leveraging these powerful programming languages for efficient and reliable software development.
• Arduino Framework/Library: Using the Arduino framework for rapid prototyping and hardware integration.
• PlatformIO: Employing PlatformIO for streamlined development and deployment.
• PWM and UART: Implementing Pulse Width Modulation (PWM) and Universal Asynchronous Receiver-Transmitter (UART) for precise control and communication.
• ASP.NET: Utilizing ASP.NET for developing the Windows application.
• Bitmap Conversion: Enabling bitmap conversion for displaying complex visual elements on the OLED device.

Trends in ambient lighting prototypes

The field of ambient lighting prototypes is evolving, influenced by several key trends:

• Interactive displays: Increasing demand for interactive and customizable lighting displays to engage users and showcase capabilities.
• Integration with Software: Emphasis on integrating hardware with sophisticated software solutions for enhanced control and functionality.
• Advanced prototyping tools: Growing use of advanced prototyping tools and frameworks to accelerate development and improve precision.
• User Experience focus: Greater focus on user experience, ensuring that prototypes are intuitive and visually appealing.
• Demonstration capabilities: Need for prototypes that can effectively demonstrate the full range of a product’s capabilities in various settings.

Endego’s competencies

Endego’s competencies in lighting and optics, combined with our expertise in hardware and software development, position us as leaders in creating innovative prototypes. Our capabilities include:

• Prototyping and development: Rapid development of hardware prototypes integrated with custom software solutions.
• Software integration: Ensuring seamless integration between hardware and software components for optimal performance.
• User Interface design: Creating intuitive and visually appealing user interfaces for controlling and demonstrating prototypes.
• Testing and validation: Rigorous testing and validation to ensure prototypes meet all performance and reliability standards.
• Regulatory compliance: Ensuring all designs comply with relevant standards and regulations.

For more detailed insights into our competencies, visit our Lighting & Optics page.

Endego’s recent project showcases our ability to develop innovative prototypes that effectively demonstrate the capabilities of our clients’ products. By leveraging cutting-edge technologies and our extensive expertise, we successfully created a hardware and software solution that meets the highest standards of performance and reliability.

For inquiries or more information about our services, feel free to contact us.

Our customer required expert support in designing the software for front car lights. The project involved implementing and verifying software on a new headlamp hardware (PCB board). The tasks included checking power and temperature conditions, implementing software protections, and ensuring reliable communication between the light module and the car’s ECU. 

Solution: Endego’s multifaceted approach 

Endego provided a specialized team responsible for hardware and software design, communication, and electronics. Our primary objective was to develop software for a new LED car light, with each LED in the matrix controlled separately via the CAN FD bus. The software implemented algorithms to control internal protections, preventing device overheating, and tuning/configuring LED current sources and power converters on the hardware PCB board. 

Key elements of our solution included: 

• Hardware and Software design: Conducting thorough design to ensure all components worked harmoniously and met the required specifications. 
• CAN and LIN protocols integration: Implementing reliable communication between the light module and the car ECU via CAN FD. 
• Algorithm development: Developing sophisticated algorithms for internal protection, temperature regulation, and power management. 
• Current source and power converter configuration: Fine-tuning the current sources and power converters to ensure optimal LED performance and longevity. 

Technologies: Advanced tools and methodologies 

Our solution leveraged a range of advanced technologies and methodologies: 

• ASPICE: Ensuring software development followed the highest standards in automotive software processes. 
• Embedded C: Utilizing Embedded C for efficient and reliable software implementation. 
• CAN FD, LIN, Ethernet: Employing the CAN FD, LIN, Ethernet protocols for high-speed and robust communication. 
• SPI and UART: Integrating SPI and UART protocols for seamless data exchange between components. 
• OTA / FOTA update: Using analog-to-digital converters for precise monitoring and control. 
• ISO26262, ISO214: Implementing boost converters to manage power efficiently. 
• Programmable Current Sources: Utilizing programmable current sources for precise control over LED brightness and power consumption. 
• AUTOSAR and Embedded Linux integration

Trends in Automotive lighting Software 

The automotive lighting software landscape is evolving rapidly, influenced by several key trends: 

• Matrix LED control: Increasing demand for matrix LED systems that allow individual LED control for enhanced lighting performance and design flexibility. 
• Advanced communication protocols: Adoption of advanced communication protocols like CAN FD for faster and more reliable data transfer. 
• Thermal management: Focus on developing software algorithms for efficient thermal management to prevent overheating and ensure component longevity. 
• Energy efficiency: Emphasis on software solutions that optimize power consumption and enhance energy efficiency. 
• Safety and compliance: Ensuring software solutions meet stringent safety standards and regulatory requirements. 

Endego’s competencies 

Endego’s competencies in lighting and optics, combined with our expertise in software development, position us as leaders in the automotive lighting industry. Our capabilities include: 

• Software development: Developing robust and efficient software solutions for complex automotive lighting systems. 
• Hardware-Software integration: Ensuring seamless integration between hardware and software components. 
• Simulation and validation: Using advanced simulation tools to validate our designs and ensure they meet all performance and safety standards. 
• Prototyping and testing: Rapid prototyping capabilities and comprehensive testing facilities to bring concepts to life. 
• Regulatory compliance: Ensuring all designs comply with relevant automotive standards and regulations. 

For more detailed insights into our competencies, visit our Lighting & Optics page. 

Endego’s recent project showcases our ability to deliver innovative software solutions for front-car lighting systems. By leveraging cutting-edge technologies and our extensive expertise, we successfully developed and implemented software that meets the highest standards of performance and reliability. 

For inquiries or more information about our services, feel free to contact us. 

Our client, a renowned Tier 1 customer serving the majority of OEMs, faced a significant challenge. They required highly skilled hardware engineers to assist in the electronic design for a new rear lighting variant. The complexity of this task demanded a partner with extensive experience and a deep understanding of advanced lighting technologies. 

Solution: Endego’s comprehensive approach 

Endego stepped up to the challenge by providing a dedicated hardware team equipped to handle all aspects of the project. Our team was responsible for the PCB design, and both analog and digital electronic design and simulation. We also ensured seamless data communication between the rear lighting (RL) and the Body Control Module (BCM). 

Key elements of our solution included: 

• PCB Design: Our experts meticulously designed the printed circuit boards to ensure optimal performance and reliability. 
• Analog & Digital Electronic Design: We leveraged our deep knowledge in both analog and digital domains to create sophisticated electronic circuits. 
• Simulation: Using advanced simulation tools, we validated our designs to ensure they met all specifications and performance requirements. 
• Data Communication: Ensuring robust and reliable data exchange between RL and BCM was critical to the success of the project. 

Technologies: Leveraging cutting-edge tools 

To deliver this solution, we utilized a range of advanced technologies: 

• Schematic and PCB design: Altium Designer was our tool of choice for schematic capture and PCB layout. 
• Electromagnetic Compatibility (EMC): We conducted thorough internal and external EMC testing to ensure compliance with stringent automotive standards. 
• Simulation tools: LTspice was used for analog circuit simulation, ensuring our designs were robust and efficient. 
• Communication protocols: We employed CAN/LIN protocols for reliable in-vehicle communication. 
• CAE tools: Our team used various CAE tools to assist in the design and analysis process. 
• Light spectrometer: The GLConnection light spectrometer played a crucial role in validating the lighting performance. 
• Load boxes and testing: We used load boxes for rigorous testing of our designs under different load conditions. 
• Collaboration tools: TeamCenter and Rational Team Concert facilitated seamless collaboration and project management across our team. 

Trends in Automotive Lighting 

The automotive lighting industry is evolving rapidly, driven by several key trends: 

• Integration with vehicle systems: Increasing integration of lighting systems with other vehicle electronics for improved functionality and safety. 
• Advanced communication protocols: Adoption of advanced communication protocols like CAN/LIN for better control and diagnostics. 
• Enhanced EMC requirements: Stricter electromagnetic compatibility requirements to ensure that lighting systems do not interfere with other vehicle electronics. 
• Simulation and testing tools: Greater reliance on simulation and testing tools to validate designs and ensure performance under various conditions. 
• Customization and flexibility: Growing demand for customizable lighting solutions to meet diverse design preferences and regulatory requirements. 

Endego’s competencies 

Endego’s competencies in lighting and optics are extensive, encompassing all aspects of design, development, and validation. Our expertise includes: 

• Optical Design: Creating efficient and innovative optical systems for automotive lighting. 
• Simulation & Validation: Using advanced simulation tools to ensure our designs meet all performance and safety standards. 
• Prototyping & Testing: Rapid prototyping capabilities and comprehensive testing facilities to bring concepts to life. 
• Regulatory Compliance: Ensuring all designs comply with relevant automotive standards and regulations. 

For more detailed insights into our competencies, visit our Lighting & Optics page. 

Endego’s recent project with a Tier 1 customer highlights our capability to tackle complex challenges and deliver innovative rear lighting solutions. By leveraging cutting-edge technologies and our extensive expertise, we ensured the successful development of a new lighting variant that meets the highest standards of performance and reliability. 

For inquiries or more information about our services, feel free to contact us. 

A Glimpse of What’s Inside the Video:

• Take a profound journey into the workings of EPS (Electronic Power Stream) power steering systems and become acquainted with Nexteer’s groundbreaking Steer by Wire and Driveline products.
• Witness the pivotal role Altair software plays in Nexteer’s static and dynamic simulations, which also encompasses injection moulding simulations via the sophisticated Inspire Mold software.
• Unmask the essence of their system – an assembly of the motor with the controller, which includes precisely chosen and engineered microprocessors, gate drivers, and power supply, meticulously brought to life by Nexteer’s adept engineers.
• Grasp how Altair HyperWorks software smoothens the transition from product idea generation to actual production, guaranteeing impeccable pre and post-processing.

Endowed by Endego’s exceptional engineering services and Altair’s powerful software, Nexteer isn’t just producing products for the present. They’re sculpting the technology that will dictate the dynamics of our future roadways in the subsequent 5, 10, 15 years. The unseen spirit of their product dwells in embedded systems and software, conjuring advanced algorithms, and performing rigorous thermal, electromagnetic, and signal analyses to ensure unparalleled product dependability.

Let’s navigate towards more breakthroughs, collaborations, and carving pathways towards a sustainable, secure, and thrilling mobility future together!

The subject of the project was a TTMA device (mobile absorber of kinetic energy when a vehicle hits a stationary or slow-moving truck, used on roads in work zones and during maintenance work).

Solution

SolidWorks software was used for the design work. The numerical model of the TTMA was prepared in Altair HyperMesh. The calculations were carried out in LS-Dyna.

The result

A prototype of the TTMA mobile absorber, meeting the requirements of European standard CEN/TS 16786:2018 for an impact speed of 100 km/h (confirmed by experimental tests).