ENGINEERING A CLEAN ENERGY FUTURE

Stafl Systems solves the most difficult challenges of the modern era of electric and hybrid-electric vehicles. Since 2010, our team has helped the top firms in the industry push the boundaries of technology and performance.

Our team members have worked for the biggest names in electric vehicle technology, and they’ve joined us because they want to be part of the pioneering work we’re doing.

Demanding Applications and Environments


Our past projects span the most demanding applications and environments, including:

  • Battery management systems and vehicle control units for electric aircraft
  • Electrical systems for a world championship-winning electric motorcycle
  • Vehicle control units and electrical systems for the fastest street-legal electric car in the world
  • Electrical systems for the first lithium-ion powered off-road vehicle prototype from a major OEM
  • Battery management system for a major OEM electric vehicle race program
  • Vehicle control unit for an all-electric underground mining vehicle

At Stafl Systems, we with our clients to develop the best systems for their applications, using our existing products or creating new ones that further push the boundaries of technology.

Demanding Applications and Environments


Our past projects span the most demanding applications and environments, including:

  • Battery management systems and vehicle control units for electric aircraft
  • Electrical systems for a world championship-winning electric motorcycle
  • Vehicle control units and electrical systems for the fastest street-legal electric car in the world
  • Electrical systems for the first lithium-ion powered off-road vehicle prototype from a major OEM
  • Battery management system for a major OEM electric vehicle race program
  • Vehicle control unit for an all-electric underground mining vehicle

We work with our clients to develop the best systems for their applications, using our existing products or creating new ones that further push the boundaries of technology.

High Voltage Applications


MINING VEHICLE

Stafl Systems provided the electronic control system and BMS for a mining vehicle. Due to the operational environment, this vehicle is continously exposed to extremely challenging and corrosive conditions. Due to the high duty cycle (20-22 hours per day), one of the challenges to solve was long-term cell-to-cell balance. Without long rest periods to perform balancing, traditional passive balancing techniques were insufficient. In this case, an active cell balancing architecture was used to enable continous cell balancing as needed across the charge and discharge cycle.

ALL-ELECTRIC SUPERCAR

We designed and developed the control system and BMS for the world’s fastest street-legal electric car. The powertrain includes two motor cores and inverters operating at 800V and capable of a maximum power output of 550kW. The vehicle architecture utilized a distributed battery pack consisting of various sub-packs connected in series. This presented a number of challenges with a distributed pre-charge which were overcome with innovative hardware and software techniques.

SOLAR-ELECTRIC AIRCRAFT

With partner companies, we designed the battery, BMS, charge control system and hybrid control system for a solar powered electric aircraft. The weight and redundancy challenges present in an aircraft application presented unique tradeoffs that needed to be studied and carefully determined.

After months of ground testing, it was very rewarding to see the system take flight and perform a number of aerial maneuvers to test the aerodynamic design and powertrain.

ELECTRIC SEMI-TRUCK

As part of a large vehicle development program, Stafl Systems consulted on the powertrain design, control strategy and battery management system for a large Class 8 semi-truck. The design included a 300 kWh 800V liquid-cooled battery system that drove 6 drive inverters.

Managing up to 1 MW of traction power safety presented a number of challenges, including safely balancing power flow between the inverters and auxiliary power sources and systems on the vehicle.

Low Voltage Applications


ELECTRIC SURFBOARD

Stafl Systems provided the battery management system for an electric surfboard. The 48V high-power battery provides one hour of run time in variable load conditions. The seawater environment and variable load presented a number of challenges to reliable operation.

INNOVATIVE ELECTRONIC CONSUMER PRODUCT

We have played a pivotal role in the development of an innovative battery-powered consumer product that is due to be launched in late 2019. Combining unique power control and battery management, we have applied our technology to a small hand-held product. Stay tuned for more updates.

Stationary Storage


STATIONARY ESS FOR DEMAND-RESPONSE

Stafl Systems was engaged to improve an existing BMS design provided by another company to correct issues that were discovered in the field. Our team performed rigorous tests on the existing design and discovered many design deficiencies and flaws in both the hardware and software. Some of these issues even led to bricked battery packs and expensive truck-rolls for field service. We proceeded to implement design recommendations to address the issues found, yielding increased reliability and accuracy of calculated values (SOC, SOH and SOE).

BATTERY-BACKED ELECTRIC VEHICLE FAST CHARGER

We are developing the power flow control system and BMS for a battery-backed electric vehicle fast charging system. This unique system combines battery-backup, AC grid interaction and solar integration.

CAREERS AT STAFL SYSTEMS

Are you interested in joining a culture by engineers, for engineers? At Stafl Systems we empower our team members to get creative and be directly involved in making impactful decisions.

Stafl Systems