Electrified System Design

TwinElectra helps customers develop next-generation electrified products by providing end-to-end engineering services spanning electric powertrains, energy systems, controls, and system integration.

Our team combines expertise in electrical, mechanical, software, and controls engineering to design complete electrified systems that deliver superior performance, efficiency, reliability, and safety. From concept development and architecture selection through validation and deployment, we support every stage of the electrification journey.

Whether developing battery-electric vehicles, hybrid platforms, industrial equipment, mobile machinery, or energy systems, TwinElectra enables customers to accelerate development while reducing technical risk.

System Architecture Development

Successful electrification begins with selecting the right system architecture.

TwinElectra supports:

• Electrification strategy development
• System requirements definition
• Powertrain architecture selection
• Component sizing and trade studies
• Energy flow analysis
• Performance optimization
• Cost and efficiency evaluation
• Technology roadmap development

Our engineering teams evaluate multiple design alternatives to identify the optimal balance between performance, cost, efficiency, durability, and operational requirements.

Electric Powertrain Engineering

We design and integrate complete electric powertrain systems including:

• Electric machines and traction motors
• Permanent Magnet Synchronous Motors (PMSM)
• Synchronous Reluctance Motors (SRIPM)
• Induction motors
• Inverters and power electronics
• Battery systems and energy storage
• Battery Management Systems (BMS)
• Energy management systems
• Vehicle Control Units (VCU)
• Power distribution systems

Our expertise spans on-road vehicles, off-highway equipment, material handling systems, industrial machinery, and specialty electrified applications.

Power Systems and Energy Management

TwinElectra develops advanced energy systems that optimize power generation, storage, and utilization.

Capabilities include:

• Generator systems and controls
• Generator synchronization
• Hybrid power systems
• Microgrids and distributed energy systems
• Energy storage integration
• DC and AC power distribution
• Power quality analysis
• Load management and optimization

Our solutions help customers improve efficiency, maximize uptime, and enhance overall system performance.

Model-Based Design and Controls Development

Electrified systems require sophisticated control strategies to maximize performance and reliability.

TwinElectra develops:

• Motor control algorithms
• Field-Oriented Control (FOC)
• Sensorless control systems
• Torque and speed control
• Energy management algorithms
• Thermal management controls
• Battery management controls
• Supervisory system controls

Using Model-Based Design methodologies, control strategies can be developed, simulated, and validated before physical hardware is available.

Digital Engineering and Validation

To reduce development risk and accelerate time-to-market, TwinElectra leverages advanced digital engineering tools throughout the development process.

Capabilities include:

• Digital Twin development
• System simulation
• Multi-domain modeling
• Hardware-in-the-Loop (HIL) testing
• Software-in-the-Loop (SIL) validation
• Controller-in-the-Loop (CIL) testing
• Automated verification and validation

These tools enable engineering teams to evaluate performance, optimize designs, and identify issues earlier in the development cycle.

Accelerating Electrification Success

TwinElectra combines deep expertise in electric machines, power electronics, controls, software, and system integration to help customers successfully navigate the transition to electrified products.

By leveraging system-level engineering, digital twins, model-based development, and advanced validation technologies, we enable organizations to reduce development time, improve product performance, and bring innovative electrified solutions to market with confidence.