Capabilities

Sprint Power is fully equipped to design complete bespoke electrical architectures and systems suitable for the next generation of electrified vehicles, including BEV, hybrid, plug-in hybrid and fuel-cell powertrains. Starting with the high-level features, attributes and requirements, we work with our customers to develop the best solution, combining the best technologies available for the end customer’s needs. Using our simulation tools along with the experience and data gained from years of experience working with every type of EV powertrain, we are able to simulate the potential benefits of each architecture to find the best solution.

We pride ourselves in taking a systematic approach to everything we do, working through every step in the ‘V cycle’, from initial requirements elicitation through to test and sign-off. We ensure that we deliver all the requirements of the system to deliver high-performing, safe and class-leading products for our customers.

We offer functional safety analysis across all levels and have a broad range of experience in developing products, from systems engineering, hardware and software development to testing, production support, servicing and decommissioning. We also specialise in process improvement and functional safety management.

Our teams can support 12V, 48V, 400V and 800V applications and can manage the integration with the vehicle’s chassis and body
control systems. Our advanced high-voltage laboratory located on site at Sprint Power is equipped with the latest rapid prototyping and test equipment, enabling our team to go from virtual design and simulation to testing hardware in a very short timescale, accelerating our development programmes to meet tight timelines.

Along with extensive design and simulation expertise, our technical teams can integrate complex powertrain systems into both existing and future vehicle platforms. Our engineers are highly skilled with extensive calibration and system validation experience to ensure each product is robust, durable and provides ongoing reliability.

“Taking a systems approach to what we do means we always ensure we produce class leading systems that meet the requirements of our customers”
–
Anthony Richmond, Chief Engineer, Systems & Integration

As the world is moving towards an all-electric future, the demand for bespoke battery systems that meet the target vehicle requirements for capacity in space, mass and cost-effective packages continues to soar. Sprint Power’s engineers work tirelessly to ensure the latest high voltage energy storage systems can overcome these challenges, so that more people can enjoy the many benefits associated with electric vehicles.

At Sprint Power we are working with many cell manufacturers, working to integrate the most appropriate cell technologies into our battery systems to suit the requirements of the end user. We have a deep understanding of the cell characteristics through our own cell characterisation testing, as well as our partners test data, to ensure we have actual performance data to work with during our cell selection and battery development process. This enables us to integrate the most appropriate cell technologies into our module and pack designs with a strong level of confidence that they will deliver class leading battery systems.

We have also developed our own Battery Management System (BMS) that is compliant with the latest ISO standards which enables us to accelerate our customer programmes. Having invested in this highly flexible, production-ready BMS, Sprint Power can provide a seamless transition through the development process to production, reducing risk, project timing and costs.

To deliver the challenging requirements many of our customers have, we take a holistic systems approach to the design and development process. We often look for opportunities to integrate associated functions and components into our battery packs to improve system efficiency, reduce weight, improve package space and provide a more cost-effective development programme and product. Examples include integrating DC/DC converters and charging interfaces, saving the client time and money.

We support our customers from initial concept engineering, through prototype development, validation testing and onto production. We offer support ranging from packages of specialist consultancy support to full production programmes using robust design methodologies and proven processes to create advanced and competitive battery systems for use across the entire low carbon mobility landscape.

“Although we are a young company, our battery development team have been in the business of developing bespoke battery systems over the past 10 to 15 years, across both hybrid and electric vehicle applications and multiple vehicle types. This depth of experience, along with our investment in development tools and facilities, enables Sprint Power to deliver unique, lightweight and highly integrated battery systems to meet the increasingly challenging requirements of our clients.”
–
Stephen Doyle, Chief Engineer, Battery Systems

Sprint Power can design and manufacture high and low voltage systems that are fully optimised for today’s electrification revolution. Our technical design specialists work with clients to understand their key requirements, while our manufacturing facilities allow the team
to cater for low to medium volume production.

Our engineering capabilities are widely applicable, which enable us to service a wide range of clients from different sectors, including automotive, motorsports, marine, defence, and off-highway transportation. Our electrical engineers and technicians have extensive knowledge and experience in designing and developing electrical architectures, high-voltage sub systems and complete cable and harness assemblies.

Sprint Power’s engineers have the ability to design harness routing and partitioning for mass optimisation, using the latest 3D environment packaging and component modelling techniques. Our advanced high-voltage laboratory enables the team’s engineers to rapid prototype and test the designs on-site, enabling us to deliver programmes with very tight time constraints.

Following a rigorous research and development process, Sprint Power’s advanced manufacturing facility enables engineers to produce high and low voltage systems, power distribution units and complete electrical architectures, equipped to perform in the most advanced and efficient low carbon vehicles.

“We follow a detailed analysis and verification process to ensure each of our development prototype designs undergoes comprehensive evaluation before series production begins.”
–
Andrew Butler, Chief Engineer, Electrical Systems

Sprint Power’s capabilities include the full development lifecycle of advanced power electronics systems. The design of both analogue and power electronics circuits can be carried out in-house, enabling the company to deliver full turnkey solutions. The creation of stateof-the-art hardware and software involves a process that covers every part of the ‘V cycle’, including requirements capture, design, implementation, verification and compliance.

Our electronics engineers are specialised in schematics, circuit layouts and integrated mechanical development for automotive power electronic components. These include ECUs for powertrain, body and chassis systems, fuel-cell and high voltage battery management units, power converters and inverters and smart power distribution systems. Our engineers work tirelessly to ensure each design fulfils functionality requirements as well as meeting durability, package and mass targets.

Sprint Power’s products can be used across the entire low-carbon mobility space including BEVs, FCEVs, HEVs and PHEVs, and within different applications including off-highway vehicles, marine and motorsport applications. Each product is designed to meet the appropriate legal and legislative standards, including environmental, electrical and mechanical statutes.

“Our advanced technical facilities provide rapid prototyping and component level testing capability to support our development programmes. Our development process ensures each design is comprehensively evaluated to deliver a production ready solution.”
–
Roland Takacs, Principal Engineer, Power Electronics and Systems

Sprint Power’s engineers run a bespoke control strategy design process, where we work closely with customers to extract all requirements. Customised systems and software architectures are created to meet all functional requirements. Control modules are comprehensively tested and verified using offline integration tests and real-time vehicle and labcar simulation procedures. Our team are experienced in developing software that meets ISO26262 safety criteria.

Our advanced in-house technical expertise enables engineers to design control systems for a wide range of applications, including supervisory controllers, torque vectoring systems, powertrain cooling systems and cabin comfort control systems for electric and hybrid vehicle applications.

Testing is conducted against the system models developed in the design phase. This Model in the Loop (MiL) testing confirms expected operation of both the algorithms and the simulated plant ahead of hardware availability, identifying early issues, minimising the required hardware test time and reducing the likelihood of component or test rig damage. Hardware in the Loop (HiL) testing enables repeatable testing, including in extreme operating conditions in a controlled and safe environment. Simulation models are used to provide representative inputs that the test piece would expect to see in its target application.

Sprint Power has the capability to design and deliver bespoke turnkey HIL and SIL simulation and testing solutions, as well as providing and integrating all required components. Simulation tools can be created to support vehicle system sizing and Model-in-Loop validation procedures.

“Our products are benchmarked against comparable systems in the market to ensure best-in-class capabilities. We work with our customers to support many different types of project, from full concept to production development programmes, to the reverse engineering of existing control systems to support prototype and mule vehicle development.”
–
Pavel Deutsch – Chief Engineer, Control Systems