Functional Safety Engineering

TwinElectra helps customers develop safe, reliable, and standards-compliant products through comprehensive Functional Safety engineering services.

As modern vehicles, industrial machines, and electrified systems become increasingly software-driven and interconnected, ensuring safe operation under both normal and fault conditions has become a critical engineering requirement. TwinElectra supports organizations throughout the functional safety lifecycle, helping identify hazards, define safety requirements, develop safety architectures, and validate safety-critical systems.

Our team has experience supporting safety programs aligned with internationally recognized standards including ISO 26262 for automotive systems and EN 13849 for machinery and industrial equipment.

Safety Lifecycle Support

TwinElectra provides support throughout the complete functional safety process, including:

• Safety planning and process development
• Hazard identification and risk assessment
• Safety requirements development
• Functional safety concept development
• Technical safety concept development
• Safety architecture design
• Safety validation and verification
• Safety case development
• Functional safety documentation

Our systems engineering approach ensures traceability from hazards and safety goals through implementation and validation.

ISO 26262 Functional Safety

TwinElectra supports the development of safety-related electrical and electronic systems in accordance with ISO 26262.

Capabilities include:

• Hazard Analysis and Risk Assessment (HARA)
• Automotive Safety Integrity Level (ASIL) determination
• Functional Safety Concepts (FSC)
• Technical Safety Concepts (TSC)
• Safety Requirements Allocation
• Safety Mechanism Development
• Fault Detection and Diagnostics
• Safety Verification and Validation
• Safety Work Product Development

We help customers integrate functional safety into the development of electrified powertrains, battery systems, motor drives, vehicle control units, and embedded software platforms.

EN 13849 Machinery Safety

TwinElectra supports machinery and industrial equipment manufacturers in achieving compliance with EN 13849 and related machinery safety standards.

Capabilities include:

• Risk Assessment and Risk Reduction
• Safety Function Definition
• Performance Level (PL) Determination
• Category Architecture Development
• Diagnostic Coverage Analysis
• Common Cause Failure Analysis
• Safety Validation
• Safety-Related Control System Design

Our experience spans industrial automation, mobile machinery, material handling equipment, construction equipment, and specialty industrial systems.

Safety-Critical Control Systems

TwinElectra develops and validates safety-related control functions for:

• Electrified powertrains
• Electric motor drives
• Battery Management Systems (BMS)
• Vehicle Control Units (VCU)
• Hydraulic and electrohydraulic systems
• Steering and braking systems
• Generator control systems
• Industrial automation platforms
• Safety monitoring and diagnostics

Our controls expertise enables the development of safety mechanisms that maintain system integrity even in the presence of hardware faults, software faults, or abnormal operating conditions.

Safety Analysis and Assessment

Our engineering teams perform a wide range of safety analyses including:

• Failure Modes and Effects Analysis (FMEA)
• Design Failure Modes and Effects Analysis (DFMEA)
• Process Failure Modes and Effects Analysis (PFMEA)
• Failure Modes, Effects, and Diagnostic Analysis (FMEDA)
• Fault Tree Analysis (FTA)
• Common Cause Failure Analysis (CCF)
• Dependent Failure Analysis (DFA)
• Diagnostic Coverage Assessment

These analyses help identify potential failure mechanisms early in the development process and guide the implementation of appropriate safety measures.

Model-Based Development and Validation

TwinElectra integrates functional safety activities with modern Model-Based Design and validation workflows.

Capabilities include:

• Requirements traceability
• Model-Based Design
• Safety-oriented controls development
• Software-in-the-Loop (SIL)
• Hardware-in-the-Loop (HIL)
• Fault injection testing
• Automated verification and validation
• Safety mechanism validation

This approach enables safety functions to be evaluated under both normal and fault conditions before deployment to production hardware.

Delivering Safe and Reliable Systems

TwinElectra combines expertise in systems engineering, electrification, embedded controls, and validation to help customers successfully develop safety-critical products.

By integrating functional safety into the development process from concept through validation, organizations can reduce technical risk, improve product reliability, accelerate certification activities, and deliver safer products to market with confidence.