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.

From this article you will know:

1. Systems Engineer – who?
2. What exactly Systems Engineer do in Automotive?
3. How to become a Systems engineer.

Projects in automotive

Projects in Automotive are very multi-dimensional and complex, the complexity of the projects is a result of the complexity of modern cars itself, which differs from cars from 10-20 years ago. The progress was mainly about increasing safety, but also adding technology and upgrading multimedia. Does that mean that older cars weren’t safe? They were, but this was only passive safety. Passive safety means equipment that works during or after the crash. Modern cars have active safety systems, that should prevent the crash.

You could ask yourself – is that technology complicated? In a word: VERY! In a modern car, you could find almost 3 kilometers of different wires.

The technology used in modern cars is intended, among other things, to protect the driver, passengers and even pedestrians (actively and passively), ensure the highest comfort of travel and provide entertainment, i.e. simply make traveling pleasant and not boring, even if nothing is interesting outside the window.

Systems Engineer – who?

First of all, I should start by explaining the difference in responsibilities for this role between the IT and automotive industries. If you are not aware of this difference, you will be in for quite a surprise during the job interview.

In IT the duties of a Systems Engineer are:

• manage and monitor all installed infrastructure systems
• installing, testing, configuring, and maintaining operating systems, application software and system management tools
• analyzing and designing process automation, e.g. using C # and Microsoft .NET Framework and various system APIs

The tasks above are significantly different from the duties of a Systems Engineer in Automotive. If you would ask us, we would say they are closer to Software Engineer.

So, is there a role in IT for a System Engineer? Yes! The closest role would be Business Analyst.

Systems Engineer in automotive

It’s not that easy to find a clear, simple definition of Systems Engineer responsibilities.
A systems engineer is a bit of an “all-rounder” – for everything and for everyone. Often, due to the project’s characteristics, two Systems Engineers with five years of experience may have completely different knowledge and experience.

In Automotive Systems Engineer is mainly responsible for:

• requirements database management
• analysis of customer requirements
• agreeing/defining requirements with the client
• writing system requirements
• supporting the creation of system architecture or just the creation  of system architecture
• ensuring compliance with the ASPICE process (in the context of the system part)
• support for other engineering competencies for which system requirements are input documents

One of the key tasks of a System Engineer is to create and maintain a requirements database, i.e. a set of documents with the client’s vision regarding how the product should look and work, but also which norms and standards the product should meet. Documentation may take different forms depending on the client.

Requirements from the customer included in the documentation are reviewed and assigned to a given competence (e.g. mechanical, validation, software, tests, electrical) and then further reviewed by the previously assigned competencies.

Requirements review is a cyclical process, it is a rare or rather impossible scenario when all issues included in the customer’s requirements are clear to engineers. Many questions / open points arise at the stage of requirements review. The task of the Systems Engineer is to fill in the gaps and clarify unclear issues. Then the cycle repeats itself until each requirement is understood, and we know exactly how to implement it and how to test it.

It’s not always as simple as it may seem. It is the responsibility of the system engineer to ensure the periodicity of the requirements review process.

A useful thing for a Systems Engineer is well-developed soft skills, he needs to be able to get along easily with people. It’s useful not only during the requirements review process mentioned above but also during negotiations with the customer. The Systems Engineer is most often the interface connecting the client’s vision with other engineers in the project.

It often happens that during the analysis of customer requirements, it is necessary to get support from other competencies that specialize in a given field (e.g. Software, Mechanical, Electrical, Validation). Then, the review and analysis of the customer’s requirements takes place in a group of engineers, but the Systems Engineer is responsible for the negotiation and clarification of requirements with the customer.

For example:

• We are able to perform the operation on a given processor, but it can be done in 200 ms and not in 100 ms as it was initially written in the design documentation.
• Selected materials will withstand 150,000 repetition cycles during validation tests and not the 200,000 cycles specified in the requirements.

Sometimes it happens that the customer expects things that are impossible to implement within the budget or equipment set for a given project, but he’s completely unaware of it. In such a situation, well-developed soft skills should come in handy again, because the Systems Engineer, as the first line of contact, should clarify this issue with the client.

Quality

Another aspect of the Systems Engineer’s responsibilities is ensuring the quality of a product. Quality in the form of creating project documentation in accordance with the norms and standards applicable in the automotive industry (e.g. ASPICE). Here, support from quality engineers is extremely important, close cooperation with “quality” is crucial to embrace the appropriate strategy and creating documentation to meet the required processes.

Are these all the duties of a Systems Engineer in the automotive industry? Of course not, and often the scale of responsibilities is much greater than what is described above, the rest can be included in the term “cooperation with other engineering competencies” and depends mainly on the characteristics of the project being implemented or even depends on the customer for whom the project is being implemented.

Systems Engineer is often responsible for topics such as:

• Cooperation with the production factory
• Performing the so-called production releases
• Memory map definition for each production release
• Supporting system tests
• Work on improving the product
• Participation in quotations for new projects
• Carrying out measurement tests
• Conducting technical workshops with the client and sub-suppliers
• Participation in product design
• Different researches on the market for product optimization or product legalization

Of course, these are not all the activities and responsibilities performed by the Systems Engineer role. For example, a project based on a camera to monitor the interior of a vehicle will require a lot of recordings for neural network training and testing.  In another project, e.g. Body Computer, the system specialist will only deal with requirements, documentation and process.

It is worth mentioning that in recent years, a Systems Engineer has been required to have knowledge of Functional Safety and Cybersecurity, at least at a basic level, despite the fact that domain specialists are employed to cover these issues in the project. It should also be noted that during the AGILE transformation of the automotive industry, it is increasingly often the system specialist who serves as the Product Owner/Function Owner.

Just how wide a spectrum of responsibilities can be covered by a Systems Engineer? Given the current scale of the diversity of projects carried out to build electronics for cars, it is difficult to say, because the number of electronic components in cars is constantly growing and each of them may have a completely different character of the project and, consequently, a completely different scope of responsibilities for the Systems Engineer. Just look at the graphic below to understand the scale of technological advancement of the modern car.

How to become Systems Engineer?

There are many possibilities, some people with experience in the industry decide to change their career and choose the path of a Systems Engineer – most often they are testers or software engineers, but they can also be quality engineers etc.

Several years of experience and a good understanding of the automotive industry make it easier to fit into the role of a Systems Engineer. A good introduction to the role of a system specialist is the position of a Requirements engineer. The main task of a requirements engineer is to write requirements and conduct reviews of existing requirements. Requirements Engineer is a good introduction to the role of Systems Engineer because the tasks performed in this role partially cover the scope of responsibilities of a systems engineer.

Summary

There are many different roles in the Automotive industry, System engineering is not the easiest one, it requires knowledge, experience and a good understanding of the business and the principles of the automotive industry. The role of a Systems Engineer is a nice balance between working with documentation and working with people. If you are open to different, often unconventional solutions, can think analytically and like working with people, this is definitely something for you.

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. 

Initiatives undertaken and implemented by Polish companies are gaining considerable publicity in this context. An excellent example of this is the SM42-6Dn hydrogen locomotive designed by PESA Bydgoszcz. The granting of its homologation by the Office of Railway Transport (Urząd Transportu Kolejowego) was met with considerable media interest, not only in the industry. The hydrogen railway fires the imagination and gives hope for a significant reduction in the carbon footprint of rail transport in the coming decades. We encourage you to read the article, in which we briefly describe:

• the history of the hydrogen railway
• the location of the Polish hydrogen railway industry – led by the Bydgoszcz-based company PESA,
• challenges and prospects for the development and uptake of hydrogen trains.

History of hydrogen rail – how has the concept developed over the years?

For more than 20 years, hydrogen locomotives and other technological solutions based on the use of this fuel have been one of the key issues in the discussion on the future of rail transport. However, the very concept of using a hydrogen fuel cell to power vehicles is much older. Its practical use in engineering was first encountered as early as the mid-1960s when it was installed on board the space shuttle that took part in the Apollo mission. Outside the space sector, however, the solution did not prove to be a breakthrough. Barriers to its development and dissemination included the low level of environmental awareness at the time and the relatively high cost of the technology.

Attempts to implement hydrogen cells in buses began as early as the 1990s, but it took until the new millennium for this technology to begin to be developed more intensively in public and private transport. Suffice it to mention that the conventional date for the first use of the term ‘hydrogen railway’ is 22 August 2003. The phrase was coined when giving a presentation on the ‘Mooresville Hydrail Initiative’ at the US Department of Transportation’s Volpe Transportation Systems Centre in Cambridge. Interestingly, the first hydrogen-powered mine locomotive was demonstrated in Canada in 2002. – which was a year earlier. As an indication of the scale of the challenges involved in implementing hydrogen technology, it took until 2006 for a hydrogen railcar to be implemented, and another 12 years for the Coradia iLint model – the world’s first hydrogen-powered commercial passenger train – to enter service. On 17 September 2018, the first two vehicles of this type were put into service in Lower Saxony.

The potential of hydrogen rail is recognized by many countries seeking to modernize their rail transport. Investments in hydrogen or hybrid (hydrogen-electric) trains are planned and underway in France, Italy, and England, among others. By using this technology, British railways intend to phase out the use of diesel trains completely by 2040. Countries outside of Europe, such as Canada, the USA, and South Korea, are also interested in the hydrogen passenger train concept. It is worth noting that work is also underway on hydrogen locomotives used, for example, for shunting work at marshaling yards or inside industrial plants.

At what stage are works on the development of hydrogen railways in Poland?

Investment in the development of hydrogen trains and locomotives is also taking place in Poland. It is worth noting that, as a priority, hydrogen-powered railway vehicles are being used as an alternative to diesel trains on non-electrified lines. Our country compares very well with the EU average in terms of the rate of electrification of lines, so it would seem that there would be less interest in hydrogen trains and locomotives. This is a mistaken impression – in Poland, there is a low level of use of the railway network, which is linked, among other things, to the limited service of non-electrified lines. If decisions are taken to increase the level of use of the rail network, hydrogen trains could prove to be a very beneficial solution for decarbonizing Polish railways.

Work on the project, which is Poland‘s first hydrogen locomotive, was started several years ago by the Bydgoszcz-based railway company PESA. The result of this project is the SM42-6Dn shunting locomotive, which is powered by two hydrogen cells. It is equipped with four asynchronous traction motors of 180 kW each and access to hydrogen tanks with a capacity of 175 kg. The hydrogen cells generate energy and, via a traction battery, power all four engines. This enables the locomotive to reach a maximum speed of 90 km/h. Importantly, the capacity of the hydrogen tanks is adapted so that one refueling allows a full 24 hours of shunting operation. It is worth adding that the SM42-6Dn shunting locomotive has a built-in obstacle recognition system and an autonomous driving system. This allows the engine driver to radio control the vehicle one-on-one when setting up trainsets.

The Bydgoszcz-based hydrogen-powered locomotive premiered at the TRAKO 2021 International Railway Fair and was approved for operation by the Railway Transport Office in mid-2023. A Polish hydrogen train will be built in the near future. PESA Bydgoszcz plans to launch the first passenger trainsets using hydrogen cells by 2026.

Why could the hydrogen train revolutionize rail transport?

The drive to decarbonize rail transport is leading more and more countries to allocate large amounts of funding to the development of hydrogen trains. What makes such high hopes for this technology?

Emission-free

One of the main reasons why hydrogen rail is attracting so much interest is its environmental potential. Burning hydrogen involves no greenhouse gas emissions. The only by-products of its use as a fuel are heat and water.

Safety and energy efficiency

A major advantage of hydrogen cells is their energy efficiency. This is largely due to the characteristics of hydrogen, which, relative to mass, has the highest calorific value and heat of combustion among fuels. Equally importantly, hydrogen trains are not inferior to conventional modes of transport in terms of safety.

Possibility of replacing diesel trains

The implementation of hydrogen trains makes it possible to reduce the number of diesel trains running on non-electrified lines. Overall, hydrogen trains can also contribute to the energy efficiency of rail transport, as hydrogen locomotives have good efficiency, being able to travel long distances without frequent refueling.

Noise reduction

An important advantage of hydrogen trains is their low noise emissions, which is particularly important for the comfort of those living close to the railway tracks.

Efficient operation at low temperatures

Hydrogen cells, which are the basis of railway hydrogen technology, are characterized by efficient operation at low temperatures.

Beneficial alternative to electrification of railway lines

Hydrogen rail is a worthwhile alternative to investment in rail electrification. This aspect is particularly relevant for markets such as North America, for example, where electrified lines are very rare.

Versatility

A point worth noting in the context of the use of hydrogen in the railway area is also its wide range of applications. Based on this technology, it is possible to modernize many different types of rail transport, including passenger, freight or industrial rail, among others.

What are the challenges of a hydrogen railway?

The road to achieving the goal of cost-effective and efficient deployment of hydrogen trains is not straightforward. One of the main problems to be tackled is the need to invest in the right infrastructure. Among other things, it is necessary to have an extensive network of hydrogen refueling stations and to train a sufficient number of employees who will have the knowledge needed to properly operate and maintain the entire system.

Another challenge associated with the hydrogen revolution in rail transport is how to obtain the hydrogen itself. Some of the fuel cell trains tested to date have used so-called grey hydrogen, which can be the product of methane reforming, coal gasification or the breakdown of water into individual elements. The use of energy- and emission-intensive processes in this context contradicts the ecological idea of hydrogen railway technology. The long-term goal is to use so-called green hydrogen, which is obtained by electrolysis using energy from renewable sources such as wind farms or photovoltaic panels.

Summary

The potential inherent in hydrogen trains means that many countries around the world are choosing to invest in this technology. The emission-free capability that modern hydrogen-powered rail vehicles will be able to provide could make them the foundation of a future ecological revolution in rail transport. However, there are more than just environmental arguments in favor of funding the development of hydrogen railways. Other important advantages of hydrogen trains include their efficiency, low noise levels, safety and efficient operation at low temperatures, among others. However, the cost-effective deployment of railway vehicles is associated with certain challenges, such as the need to create the appropriate infrastructure, educate the workforce, as well as the efficient acquisition of green hydrogen.

The design of hydrogen-powered rail vehicles is an endeavor that requires the specialists involved to have the necessary know-how and many years of experience in implementing advanced technological projects in the area of rail transport. Knowledge of the specifics of this sector is crucial, as the nature of rail vehicle production differs significantly from the standards according to which, for example, industrial design in the automotive industry is carried out. At Endego, we have specialized in conducting technology projects for companies in the rail industry for many years. We have successfully cooperated with leading national railway companies such as PESA, the developer of the first Polish hydrogen locomotive, and Polski Tabor Szynowy – Wagon, among others.

Are you looking for a proven engineering team with experience in designing key elements that affect the functionality, efficiency and aesthetics of rail vehicles? Contact us and let’s create the future of rail transport together!

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. 

Hydrogen-powered vehicles are one of the fastest growing areas in the public transport sector. This is influenced, among other things, by various subsidy programmes to support the implementation of clean public transport. In the remainder of this article, we will analyse, among other things, why there is so much interest in hydrogen buses, what their main advantages are, what their general principle of operation is, and what the current situation is regarding the use of this type of low-emission vehicles in Poland and around the world. 

Hydrogen bus – one of the cornerstones of public transport of the future 

Increasing the energy efficiency of vehicles and the use of renewable energy are currently among the strategic objectives of European transport and energy policy. The motivation for taking action in this direction is primarily the desire to prevent progressive climate change and an increase in air pollution. As road transport is a significant factor negatively affecting urban air quality, public transport has become one of the areas of particular focus in the development of new, greener technologies. 

The process of modernising public transport and transforming it towards low-carbon modes of transport has become multifaceted over the years. An important part of the focus in recent decades has been on electromobility, understood mainly as BEVs (Battery Electric Vehicles), i.e. vehicles powered by electricity stored in rechargeable batteries. During this time – somewhat in the shadows, one might say – there has also been systematic progress in the use of hydrogen technology for propulsion in buses and trams. This has been fostered by various initiatives such as, among others, the international CHIC project, which aimed to support the market introduction of hydrogen fuel cell buses. 

For some time now, we have also been able to observe the rise of public transport based on fuel cells in Poland. On the streets of larger and smaller cities in our country, it is increasingly common to see hydrogen buses running on a regular basis, attracting passengers with modern, ergonomic equipment and practical amenities such as free Wi-Fi or USB sockets for charging phones. The development of the situation in this area is evidenced by one of the indicators for achieving the goals set out in the Polish Hydrogen Strategy until 2030 with an outlook until 2040: 

• 100 to 250 buses by 2025, 
• 800 to 100 buses by 2030. 

It is worth asking at this point why such high hopes are being pinned on hydrogen buses. The most important factor that determines the belief in the breakthrough nature of this type of vehicle is the many advantages of hydrogen as a fuel. What are the most important advantages of using hydrogen fuel cells to power city buses? 

• Short full refuelling times – this is one of the key strengths of hydrogen buses and a very big advantage over strictly electric-based vehicles. A hydrogen bus (FCEV – Fuel Cell Electric Vehicle) takes on average around 15 minutes to refuel, while a battery bus (BEV) can require up to several hours to recharge (with plug-in chargers). 
• Good range – advocates of hydrogen buses point to their high efficiency. Using hydrogen fuel cells, the bus may be able to cover up to 400 kilometres on a single fill-up. 
• Low-emission – a very important issue in the context of the continuing interest in modern hydrogen-powered city buses is their environmental credentials. Assuming they use so-called green hydrogen (hydrogen produced by electrolysis of water using renewable energy), their operation does not involve CO2 emissions, making them zero-emission vehicles. However, even in the case of the use of so-called grey hydrogen (hydrogen produced by reforming natural gas or other hydrocarbons derived from oil refining), we can talk about the low-emission performance of the buses using it. In the course of the operation of hydrogen cells, besides electricity, only heat energy and water are produced. 
• Safety – a properly designed hydrogen bus is a vehicle that is not only environmentally friendly and economical but also safe. This is due, among other things, to the properties of hydrogen itself, which is much lighter than air and has a high auto-ignition temperature in air of 585°C. This is significantly higher than, for example, petrol, which has an auto-ignition temperature of around 215°C. The lightness of hydrogen means that, in the event of a leak, it instantly becomes airborne, thus reducing the risk of ignition. The high auto-ignition temperature in the air, on the other hand, makes it difficult to initiate the combustion process of hydrogen with air without additional agents, which is important in terms of safety in the event of a collision. 
• Low-temperature efficiency – hydrogen buses do not experience a drastic reduction in driving performance at lower temperatures. 

There are also other reasons why more and more urban centres are choosing to invest in hydrogen buses. Worth mentioning in this context are: 

• the low noise and vibration levels generated by this type of public transport, 
• no load on the local power grid, 
• various subsidy programmes to support the hydrogen transition of public transport in the area. 

How does a modern hydrogen bus work? 

Many people do not realise that hydrogen buses are essentially electric vehicles. They use hydrogen fuel cell kits to produce electricity. The by-products of this process are only heat energy and water. The electricity generated is channelled into the bus’s propulsion system and, in the case of many models of these vehicles, into a battery. The purpose of such a battery is to provide support to the hydrogen fuel cells when there is an increased energy requirement of the electric vehicle. Figuratively speaking, then, modern hydrogen buses are in fact electric vehicles with their own ‘mini-electric power plants’ on the roofs. 

What is the principle behind the hydrogen cells used in buses? 

To better understand how a hydrogen bus works, it is worth discussing the operation of the hydrogen fuel cell, which is used to produce the electricity that powers the propulsion system of this modern vehicle. The hydrogen fuel cell consists of three basic components, which include: 

• anode, or negative electrode, 
• cathode, or positive electrode, 
• proton exchange membrane separating the cathode and anode – often in the form of a polymer electrolyte. 

The hydrogen fuel cell uses a reverse electrolysis reaction involving oxygen from the air and hydrogen supplied from tanks mounted on the bus. It allows electricity to be generated while the vehicle is in use, producing only heat and water vapour, which is removed to the outside. As a result, no harmful substances are produced. This allows the hydrogen bus to be called emission-free. The electricity produced goes to the vehicle’s propulsion system and to the battery that supports the cells in the event of higher energy demand. 

What is the mechanism of the hydrogen bus? 

How is a set of hydrogen cells able to power a modern bus? It is a multi-stage process that is worth analysing in detail. 

1. The stage that initiates the whole process of energy flow in the vehicle is the supply of oxygen to the hydrogen cell in the form of air purified by special filters and hydrogen from tanks usually located on the roof of the vehicle. The hydrogen is transported to the anode, while the oxygen is transported to the cathode. Importantly, the surfaces of both electrodes are coated with a catalyst. 
2. Hydrogen fed to the anode initiates a reaction with the catalyst. Its oxidation occurs, causing it to decay into electrons and protons in the form of hydrogen cations. 
3. The proton exchange membrane only allows protons to pass through it, which pass to the cathode side, while it blocks the flow of electrons resulting from the decomposition of hydrogen. 
4. Electrons from the oxidation of hydrogen are directed to the cathode by an external electrical circuit, creating a current that is used to drive the bus’ electric motor. 
5. When the electrons are transported to the cathode, they bind to the oxygen there and are reduced to oxide anions. 
6. Protons resulting from the oxidation of hydrogen pass to the cathode through the membrane, where they react with oxide anions to produce water and heat energy. 

The electricity generated by the hydrogen fuel cell kit is supplied to the bus’s electric motor, as well as to the traction battery that acts as a booster. With the electricity produced, the vehicle can move. As a by-product of the cells’ operation, water and heat are removed to the outside. 

Hydrogen buses in Poland – what is the current situation? 

As a result of investments made in recent years, Poland is slowly becoming an increasingly important player in the European hydrogen bus market. The number of Polish cities served by carriers adding more hydrogen fuel cell buses to their fleets is increasing. Among the vehicles being tested and implemented in our country are hydrogen buses from foreign concerns such as Mercedes, for example, as well as from Polish companies. Crown examples of domestic hydrogen bus models include the NesoBus, produced at the newly established Świdnik plant, as well as the Solaris Urbino 12 Hydrogen. 

The NesoBus brand was established as an initiative belonging to the Polsat Plus Group of companies and ZE PAK. The signature bus was designed from the ground up as a hydrogen construction powered by green hydrogen, which makes it an emission-free solution. It is characterised by, among other things: 

• impressive range – up to 450 km, 
• short refuelling time – up to 15 minutes, 
• high efficiency – it can run without refuelling for up to 2 days; it consumes on average about 8 kg of hydrogen per 100 km and its tanks hold 37.5 kg of hydrogen, 
• satisfactory capacity – accommodates up to 93 passengers, including up to 37 seated, 
• the high quality of the hydrogen fuel cells used, sourced from the leading supplier of this type of solution, Ballard, 
• the robustness of the hydrogen tanks – particularly important in terms of vehicle safety – supplied by the specialists in this field, Hexagon, 
• an ergonomic, modular design, which allows components of the entire hydrogen system to be replaced in the future with other, better-performing components, 
• construction based on the use of modern, lightweight materials and efficient air-conditioning and heating systems – contribute to a reduction in the need for electricity as well as fuel consumption in the form of hydrogen, 
• modern design, which was the responsibility of Torino Design, a company with extensive experience of working with the automotive sector. 

Also worth noting is the evocative name of the NesoBus, the first four letters of which are derived from the phrase: “No Exhaust Emissions, Cleanses (the air)”. It derives from the fact that this Polish hydrogen bus contributes to the elimination of emissions of harmful substances, including carbon dioxide, nitrogen oxides and particulates, in particular fine PM 2.5. Rybnik, for example, has already decided to implement NesoBuses in its public transport fleet, and in time it will also be possible to see them in Gdańsk or Chełm, for example. 

In the field of industrial hydrogen bus design and production, Solaris Bus & Coach is also highly successful. This is borne out by data which shows that this manufacturer’s share of the European hydrogen bus market was as high as 44.5 % in 2023. Polish hydrogen buses Solaris Urbino 12 Hydrogen are an important element of public transport in more than 20 towns and cities located in various countries of the Old Continent, including, among others, the Netherlands, Italy, Germany, Austria or Sweden. In Poland, this model can be found, for example, on the streets of Konin or Poznań. On board the Solaris Urbino 12 Hydrogen, 85 passengers can travel in comfort and safety, including 37 in seating positions. 

It can be said with full conviction that the Polish hydrogen bus ‘has more than one name’. Polish companies such as Autosan, Arthur Bus and Pilea, among others, are also involved in the production of this type of modern means of public transport. Local authorities are encouraged to invest in hydrogen-powered buses through various subsidy programmes, including, among others, Green Public Transport, operated by the National Fund for Environmental Protection and Water Management (NFOŚiGW). Other initiatives are also worth mentioning, such as the subsidies offered by the Centre for EU Transport Projects. 

In doing so, it should be noted that for the development of public transport based on hydrogen cells, it is not only necessary to invest in the fleet but also in the appropriate infrastructure. This includes, among others: 

• hydrogen filling stations – such places already exist, e.g. in Poznań, where near the Miłostowo tram terminus there is a publicly accessible 24/7 hydrogen filling station with three dispensers, set up by Orlen, 
• plants for the production of green hydrogen, which would be able to meet the market demand for this element, 
• transport infrastructure to ensure the efficient movement of hydrogen from the production site to the individual filling stations. 

Harnessing the potential inherent in hydrogen buses requires systemic action and large financial outlays, but the benefits – both in the short and long term – make this the right direction for Poland to take. 

Hydrogen buses – an important part of the modern urban fabric 

Modern city buses using hydrogen fuel cells combine three aspects that can be summarised as ‘3 x E’: 

• ecology, 
• economics, 
• ergonomics. 

On the one hand, they are low- or – in the case of using green hydrogen – zero-emission electric vehicles whose only by-products are water and heat. On the other hand, they are characterised by good range, high efficiency and short charging times, making them financially viable in the long term. A third, and equally important, is the high level of comfort they provide for the passengers who move with them, including those with disabilities. It is therefore no surprise that an increasing number of Polish cities aspiring to be modern, climate-neutral and friendly to their inhabitants have innovative hydrogen buses on their streets. 

Designing vehicles based on hydrogen technology, such as modern city buses equipped with hydrogen cell kits, for example, requires a very high level of interdisciplinary competence from the specialists involved. At Endego, we have many years of experience in leading and implementing technology projects in cooperation with bus manufacturing companies. As part of our comprehensive services, we provide active support at every stage of the respective project: from the development of the initial concept to the start of series production. 

Are you planning the design of a modern green energy city bus and need the support of qualified engineers and designers to realise this ambitious project? Get in touch with us! 

If you would like to learn more about the technology projects we have completed for bus manufacturers, we encourage you to read another article on our blog: Endego: A revolutionary approach in bus design.