Hybrid Energy Storage System for a German GreenTech Startup

Client Overview

The client, a German Green Tech startup, is developing an innovative hybrid energy storage device designed to significantly reduce CO2 emissions. This eco-friendly system combines a Li-Ion battery with an H2 fuel cell, making it lighter, smaller, and more cost-effective. Primarily targeted for automotive aftermarket applications, the system is also well-suited for high-end niche markets, including caravans and ships.

Project Objectives

  • Develop an embedded control system for the Zero Emission Power Box prototype.
  • Implement real-time monitoring and control of energy storage components.
  • Enable seamless communication with sensors, actuators, and fieldbuses.
  • Support software commissioning and optimization through test bench trials.

Technologies Used

  • Embedded Development: LabVIEW, cRio (National Instruments)
  • Communication Protocols: CAN Bus

Team Structure

  • Team Members: 1 embedded system developer
  • Roles: Control system development, sensor integration, test bench support

Key Development Activities

✅ State Machine-Based System Control: Designed and implemented an optimized control strategy for system performance and efficiency.

✅ Sensor & Actuator Integration: Developed real-time communication interfaces to manage all system components effectively.

✅ Fieldbus Configuration (CAN Bus): Configured robust communication between embedded controllers and power management units.

✅ Graphical User Interface (GUI): Created a status display to provide real-time insights into system performance and diagnostics.

✅ Prototype Software Commissioning: Successfully deployed and tested software on the cRio prototype control unit.

✅ Test Bench Optimization & Support: Assisted in test bench trials to fine-tune optimal operating points and system performance.

Results & Impact

The first prototype of the hybrid energy storage system was successfully developed and transferred to the initial testing stage. The solution is now progressing toward further optimization and market readiness, paving the way for a more sustainable and efficient energy storage alternative.

Conclusion

By integrating advanced embedded software development with real-time control and diagnostics, this project sets a new standard for hybrid energy storage solutions. The successful prototype development marks a significant milestone toward reducing CO2 emissions and advancing green mobility.

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