Hypermotive announce their HyperFlex M-PDU programme

Hypermotive are pleased to announce that their HyperFlex M-PDU project has been awarded a grant from The Department for Business and Trade (DBT), through The Advanced Propulsion Centre (APC) and Niche Vehicle Network (NVN).  Hypermotive’s HyperFlex project is focussed on assessing the technical and commercial feasibility of a modular design approach to developing high voltage Power Distribution Units (PDUs) suitable for a wide variety of applications. Conceptually, M-PDU is a modular, scalable and configurable high voltage, high current Power Distribution Unit (PDU) providing the electrical integration hub for low and mid-volume vehicle programmes looking to integrate battery electric and fuel cell powertrains using commercial off-the-shelf (COTS) components.

Hypermotive have almost a decade of experience as a tier-1 designer and manufacturer of electrical integration products (including, but not limited to PDUs, DCDC converters, junction boxes, fuse boxes and wiring harnesses) for a wide range of applications including automotive, commercial vehicle, industrial and off-highway.  Development timescales and budgets are continually being compressed for OEMs, putting pressure on engineers to look for pre-validated COTS solutions. A modular, scalable design approach, providing the maximum level of flexible specification whilst maintaining a level of configurability to accommodate unique vehicle requirements, should help to dramatically reduce the cost and time required for bespoke design.

With a wealth of experience designing PDUs for customer programmes, Hypermotive understand the need for bespoke designed PDUs will likely still remain for many solutions because every application, customer and vehicle sector has differing requirements from their PDU such as voltage level, current carrying capacity, connector type, orientation and packaging envelope. However, some of the core sub-components are repeatedly specified in designs, driving to the conclusion that with consideration to electrical design, mechanical design, safety integrity, and control software, and packaging, a modular, scalable approach may be feasible and remove the barriers to entry for numerous applications. With a positive outcome from this study, rationalising a number of the key specifications for a wide range of applications and customers could support a positive business case for more niche customer, zero emission development programmes. Supporting vehicle level compliance to ISO 26262 and Cyber Security will create significant added value, particularly in niche vehicle applications.

HyperFlex M-PDU is an exciting 3-month sprint programme, under-pinned by Hypermotive’s knowledge of sector requirements, culminating in a potential design philosophy that could help drive the development of future COTS PDU solutions for the niche vehicle market.