Aachen, September 2024 – FEV, a leading global innovation driver in several sectors, will present its solutions for reducing CO₂ emissions in the transportation of passengers and goods at IAA TRANSPORTATION in Hanover from September 17 – 22 for the first time. The company develops hydrogen combustion engines and fuel cell propulsion systems, which will play a decisive role in the transformation of the mobility sector. Equally important are modern battery electric propulsion solutions. FEV is also making significant developments in this area and will be showcasing them at the leading trade fair for logistics, commercial vehicles and the transportation sector in Hanover.

The mobility sector is responsible for around one fifth of total global carbon emissions. The defossilization of this sector is therefore one of the biggest tasks of the coming years. FEV is committed to help shaping this process successfully with solutions that are innovative and open to various technologies.

“Cutting the CO₂ emissions in the transportation sector can only be achieved through a sensible mix of different technologies. Hydrogen demonstrates its potential for reducing CO₂ emissions in fuel cells and combustion engines for long-distance applications. In urban and regional environments, battery-powered drives are another effective solution for the emission-free mobility of tomorrow,” said Dr. Patrick Hupperich, CEO of the FEV Group. “Synthetic fuels should also not be underestimated when considering the total fleet of over 300 million vehicles in the EU alone. FEV brings a high standard of expertise and experience in all these areas from more than 45 years in the development of innovative engine and propulsion technology and is involved across all technologies.”

At the IAA TRANSPORTATION, the Aachen-based company with locations on six continents will be demonstrating the wide range of its sustainable solutions. These range from long-distance transportation to last-mile delivery. The portfolio on display comprises a battery-powered electric drive for pedelecs and e-bikes, an electric drive unit for commercial vehicles and a hydrogen combustion engine for non-road machinery applications. A fuel cell solution for light trucks up to 7.49 tons rounds off the exhibits and reflects the versatility and scalability of FEV’s solutions.

Climate-neutral hydrogen combustion engine

Developed by FEV together with project partner Kohler Engines Co., the 2.5-liter direct injection engine delivers 55 kW of power with a maximum torque of 315 Nm. FEV contributed its expertise in engine development to the design of the unit, which is designed for hydrogen operation. Extensive simulation and performance tests were also carried out. Emission measurements proved that the unit, originally designed as a diesel engine, no longer produces any relevant pollutant emissions. The simulation tool chain and engine control software specially developed at FEV for hydrogen combustion engines was used for this purpose.

Fuel cell system for light commercial vehicles

Another milestone is the fuel cell concept that FEV has realized for the Italian IVECO Group. FEV is the exclusive development partner responsible for the electrification of the Light Commercial Vehicle (LCV) fleet.

At the IAA TRANSPORTATION, FEV presents a 90 kW fuel cell module that the engineers have tailored for optimized integration into the existing IVECO DAILY model range. In this project, the engineering service provider was responsible for the mechanical, electrical and thermal integration of the fuel cell system and the hydrogen tanks. FEV’s experts were also responsible for the gateway development and implementation of the specially developed energy management system for fuel cell powertrains.

The IVECO DAILY, which weighs up to 7.2 tons when fully loaded, has a range of up to 350 km with its 140 kW drive. The 12 kg of hydrogen in the 700 bar tanks can then be refilled in less than 15 minutes. As an energy reserve, the vehicle has a 37 kWh lithium-ion battery that recuperates braking energy and makes it available during peak loads.

Alongside innovative electric propulsion solutions, FEV presents solutions for the holistic development of sustainable commercial vehicles and buses: from the conception and design of individual components and assemblies to the integration and testing of entire vehicles – from mechanical components to complex lighting and sound applications.

Turnkey vehicle development

As a globally leading engineering service provider, FEV has in-depth expertise in all application areas of vehicle development. This includes the design and optimization of vehicle bodies and electronic components as well as the development of sustainable propulsion systems. The range of services also includes software development for driver assistance systems, including autonomous vehicles. The portfolio is complemented by an extensive benchmarking program and a multi-award-winning range of consulting services for strategic topics and management questions in sustainable corporate development.

Visitors to the IAA TRANSPORTATION are cordially invited to convince themselves of FEV’s innovative solutions at booth C-14 in hall 24.

About FEV

FEV has always pushed the limits.
FEV is a globally leading engineering provider in the automotive industry and internationally recognized leader of innovation across different sectors and industries. Professor Franz Pischinger laid the foundations by combining his background in academia and engineering with a great vision for continual progress. The company has supplied solutions and strategy consulting to the world’s largest automotive OEMs and has supported customers through the entire transportation and mobility ecosystem.

As the world continues to evolve, so does FEV.
That’s why FEV is unleashing its technological and strategic expertise into other areas, applying its forward thinking to the aerospace and energy sectors. Thanks to its software and system expertise, the company also leads the way making intelligent solutions available to everyone. FEV brings together the brightest minds from different backgrounds and specialties to find new solutions for both current and future challenges.

But FEV won’t stop there.
Looking ahead, FEV continues to push the limits of innovation. With its highly qualified >7,100 employees at more than 40 locations globally, FEV imagines solutions that don’t just meet today’s needs but tomorrow’s. Ultimately, FEV keeps evolving – to a better, cleaner future built on sustainable mobility, energy and software that drives everything. For the company’s partners, its people and the world.

#FeelEVolution

Aachen, August 2024 – FEV.io, the software brand of global engineering service provider FEV, presents an intelligent voice assistant that enables a completely new kind of user experience inside the vehicle. The solution uses generative AI to understand the needs of drivers and passengers and provide optimal solutions in real time.

The holistic development approach by FEV.io is based on an innovative AI framework. The generative AI, which is integrated into the core of the voice assistant, accesses data from a personal, secure cloud profile of the driver and uses live vehicle data as well as environmental parameters to search for the best possible support for the user in real time.

“In today’s digital and connected world, a new kind of user experience in the vehicle is increasingly expected,” said Dr. Johannes Richenhagen, Managing Director of FEV.io. “Our international team analyzes various everyday situations, outlines possible challenges and develops tailor-made, holistic solutions that guarantee the best possible user experience for the driver. We accompany the development process from the initial idea to the finalized and tested solution ready for series production. And of course, data security and privacy are guaranteed.”

Seamless and intuitive user experience
The times when specific keywords had to be memorized to operate voice assistants are now a matter of the past. The FEV.io approach offers independent solutions for everyday questions. The following example illustrates the complexity of supposedly simple everyday situations in which the new FEV voice assistant can provide added value: From the initial questions “When do I have my next appointment? What do I need to prepare for it?”, further questions such as “Will I get there on time given the current traffic situation? Is my battery charge or fuel level sufficient for this route?” The assistance system automatically considers these subsequent steps and offers appropriate solutions.

The system can also control other vehicle functions like the air conditioning or the infotainment system. From the simple expression “I´m tired”, the generative AI derives measures such as playing stimulating music or lowering the temperature in the interior. The system also determines the next parking area as a navigation destination and encourages the driver to take a break there. In this way, AI can even increase the safety of the driver and other road users.

FEV combines its expertise in software development with many years of experience in vehicle development. The team draws on a global network of specialists providing customized solutions.

About FEV

FEV has always pushed the limits.
FEV is a globally leading engineering provider in the automotive industry and internationally recognized leader of innovation across different sectors and industries. Professor Franz Pischinger laid the foundations by combining his background in academia and engineering with a great vision for continual progress. The company has supplied solutions and strategy consulting to the world’s largest automotive OEMs and has supported customers through the entire transportation and mobility ecosystem.

As the world continues to evolve, so does FEV.
That’s why FEV is unleashing its technological and strategic expertise into other areas, applying its forward thinking to the aerospace and energy sectors. Thanks to its software and system expertise, the company also leads the way making intelligent solutions available to everyone. FEV brings together the brightest minds from different backgrounds and specialties to find new solutions for both current and future challenges.

But FEV won’t stop there.
Looking ahead, FEV continues to push the limits of innovation. With its highly qualified >7,100 employees at more than 40 locations globally, FEV imagines solutions that don’t just meet today’s needs but tomorrow’s. Ultimately, FEV keeps evolving – to a better, cleaner future built on sustainable mobility, energy and software that drives everything. For the company’s partners, its people and the world.

#FeelEVolution

Aachen, August 2024 – FEV, a globally leading innovation driver for sustainable mobility, has developed a 48 V electric powertrain for Toyota. The latest generation of Toyota’s Accessible People Mover (APM) operated with this technology ensures that athletes, staff and officials can travel the “last mile” in a CO2-neutral way at an international sports event taking place in Paris this summer. The Japanese car manufacturer is deploying around 250 APMs in Paris to transport competitors from their accommodation to the sports venues and to transport physically handicapped visitors.

The vehicles are designed for up to six people (one driver and five passengers) and allow easy access for wheelchair users. Larger items of luggage, such as athletes’ equipment, can also be transported in the passenger compartment.
FEV has developed the 12.3 kW powertrain, accelerating the vehicle up to 20 km/h, in record time. One charge of the 9 kWh Li-ion battery pack is sufficient for distances of up to 100 km on a maximum gradient of 20 percent.

“With the development of the APM powertrain, we were able to create a reliable and technically mature propulsion concept and hand it over to the customer in April of this year after only around 24 months,” said Dr. Michael Stapelbroek, Vice President Electric Powertrain at FEV.
With this project, FEV underlines its role as a leading global development service provider for sustainable mobility solutions and has taken on the complete system design, set-up and monitoring of the supply chain as well as the development and integration of the powertrain, including extensive testing and validation. In addition to engineers from Germany, the project team also included experts from Italy, Turkey and India.
Stapelbroek explained the recipe for success behind the APM powertrain: “With an agile project approach, our international team was able to exploit the potential of our entire network. This also enabled us to successfully overcome the challenges posed by the tight project schedule.”

The features and functions of the powertrain unit were already tested on prototype vehicles during the design phase. This gave the project team time for extensive functional validation and thus a high level of technical maturity of the entire electric powertrain at an early stage.

About FEV

FEV has always pushed the limits.
FEV is a globally leading engineering provider in the automotive industry and internationally recognized leader of innovation across different sectors and industries. Professor Franz Pischinger laid the foundations by combining his background in academia and engineering with a great vision for continual progress. The company has supplied solutions and strategy consulting to the world’s largest automotive OEMs and has supported customers through the entire transportation and mobility ecosystem.

As the world continues to evolve, so does FEV.
That’s why FEV is unleashing its technological and strategic expertise into other areas, applying its forward thinking to the aerospace and energy sectors. Thanks to its software and system expertise, the company also leads the way making intelligent solutions available to everyone. FEV brings together the brightest minds from different backgrounds and specialties to find new solutions for both current and future challenges.

But FEV won’t stop there.
Looking ahead, FEV continues to push the limits of innovation. With its highly qualified >7,100 employees at more than 40 locations globally, FEV imagines solutions that don’t just meet today’s needs but tomorrow’s. Ultimately, FEV keeps evolving – to a better, cleaner future built on sustainable mobility, energy and software that drives everything. For the company’s partners, its people and the world.

#FeelEVolution

Aachen/Hamburg, Germany, July 2024 – Last month, the world’s leading engineering services provider FEV unveiled its new brand FEV aerospace. This week, the company moved into its own office. FEV’s aerospace experts are now located in the “ZAL II” building extension of the Center of Applied Aeronautical Research in Hamburg-Finkenwerder.
It has now been officially opened by the First Mayor of the Free and Hanseatic City of Hamburg, Dr. Peter Tschentscher.

“The ZAL in Hamburg-Finkenwerder is the leading technological research and development platform for civil aviation in Germany,” says Dr. Christian Eschmann, Director Aerospace at FEV. “This is the perfect environment for us, especially as we are in close proximity to our customers. We are therefore very excited to be developing state-of-the-art solutions for the aerospace industry from our new office.”

FEV has been developing sustainable innovations and technologies in the fields of mobility, energy and software for over 40 years. Under the FEV aerospace brand, the company is bundling its engineering and consulting expertise to make an even more targeted contribution to the sustainability of the aerospace sector in the future. Environmentally friendly propulsion systems are just as much a part of FEV aerospace’s portfolio as intelligent software solutions.

About FEV

FEV has always pushed the limits.
FEV is a globally leading engineering provider in the automotive industry and internationally recognized leader of innovation across different sectors and industries. Professor Franz Pischinger laid the foundations by combining his background in academia and engineering with a great vision for continual progress. The company has supplied solutions and strategy consulting to the world’s largest automotive OEMs and has supported customers through the entire transportation and mobility ecosystem.

As the world continues to evolve, so does FEV.
That’s why FEV is unleashing its technological and strategic expertise into other areas, applying its forward thinking to the aerospace and energy sectors. Thanks to its software and system expertise, the company also leads the way making intelligent solutions available to everyone. FEV brings together the brightest minds from different backgrounds and specialties to find new solutions for both current and future challenges.

But FEV won’t stop there.
Looking ahead, FEV continues to push the limits of innovation. With its highly qualified >7,100 employees at more than 40 locations globally, FEV imagines solutions that don’t just meet today’s needs but tomorrow’s. Ultimately, FEV keeps evolving – to a better, cleaner future built on sustainable mobility, energy and software that drives everything. For the company’s partners, its people and the world.

#FeelEVolution

Aachen/Grünwald, Germany, June 2024 – FEV, a leading global engineering service provider and innovation driver for sustainable mobility and energy solutions, and Certina Group, a family-run industrial holding company, have reached an agreement on the acquisition of the global Software & Testing Solutions (STS) business by Certina. The parties have also agreed not to disclose the terms of the transaction.

As a business segment of FEV, STS has established itself worldwide as an outstanding provider of turnkey test hardware and software products since 1995. Certina will take over this division completely and continue it under the brand name Software and Testing Solutions.

“The automotive industry, and the market for engineering service providers in this sector, are undergoing rapid change. We have therefore come to the conclusion that a sale to an independent partner is best suited to secure the future of our test systems division and at the same time ensures the support of FEV’s strategic interests,” said Patrick Hupperich, CEO of the FEV Group, explaining the decision to sell the FEV STS business to Certina Group, a German industrial holding company that is currently comprised of more than 20 companies in five business sectors. The Group has extensive experience in the management and positioning of medium-sized companies and in plant engineering.

“Since our foundation, we have invested according to the principles of sustainability and continuity,” said Stefan Brungs, managing partner of the Certina Group. “We want to continue the STS business and are building on its management, resources and networks to take it to the next level by leveraging synergies with other companies in our holding.”

In terms of ongoing customer relations and market approach, FEV will co-operate in partnership with STS, now a part of the Certina Group, by jointly developing test systems and creating growth potential for both companies. This also includes research and development projects. FEV will offer end-user market and technical engineering know-how for powertrain development and testing while STS will drive the development of test bench systems that meet the testing needs of vehicle propulsion enabling CO₂-neutral mobility.

The STS team will work independently and entrepreneurially at five locations worldwide. The STS headquarters are located in Auburn Hills/USA. Allen Arnoldy has been appointed CEO. He most recently was responsible for the global test systems business at FEV.

About CERTINA Group

The CERTINA Group is a family equity investor and a family-run industrial holding company with a focus on European SMEs in transition and special situations. The CERTINA Group can look back on more than 25 years of investment experience with over 65 successful transactions in various industries.

CERTINA invests according to the principles of sustainability, continuity and corporate responsibility, thus creating long-term value for generations in the interests of employees and society. Some companies have been part of the CERTINA Group for over 20 years.

The group currently comprises 21 companies in five sectors and generates a turnover of 1 billion euros with 4,100 employees.

CERTINA: The sustainable investor. Operational | Visionary | Continuous.

About FEV

FEV has always pushed the limits.
FEV is a globally leading engineering provider in the automotive industry and internationally recognized leader of innovation across different sectors and industries. Professor Franz Pischinger laid the foundations by combining his background in academia and engineering with a great vision for continual progress. The company has supplied solutions and strategy consulting to the world’s largest automotive OEMs and has supported customers through the entire transportation and mobility ecosystem.

As the world continues to evolve, so does FEV.
That’s why FEV is unleashing its technological and strategic expertise into other areas, applying its forward thinking to the aerospace and energy sectors. Thanks to its software and system expertise, the company also leads the way making intelligent solutions available to everyone. FEV brings together the brightest minds from different backgrounds and specialties to find new solutions for both current and future challenges.

But FEV won’t stop there.
Looking ahead, FEV continues to push the limits of innovation. With its highly qualified >7,100 employees at more than 40 locations globally, FEV imagines solutions that don’t just meet today’s needs but tomorrow’s. Ultimately, FEV keeps evolving – to a better, cleaner future built on sustainable mobility, energy and software that drives everything. For the company’s partners, its people and the world.

#FeelEVolution

Aachen/Berlin, June 2024 – FEV, a globally leading engineering service provider for sustainable innovations and technologies in the fields of mobility, energy, and software, is expanding its service portfolio and launches FEV aerospace at Europe’s leading aerospace trade fair ILA Berlin. The new brand brings together the company’s engineering and consulting expertise to make an even more targeted contribution to the sustainability of the aerospace sector in the future.

“The inception of FEV aerospace is a logical and important strategic step to officially communicate and offer FEV’s expertise and many years of experience in this complex field to the outside world,” said Dr. Patrick Hupperich, CEO of FEV Group, in the run-up to ILA Berlin. “FEV aerospace addresses both traditional customers from the aviation and space industry as well as new companies in emerging fields such as Advanced Air Mobility and NewSpace.”

As for the entire traffic and transportation sector, sustainability will be the key innovation driver for the aviation industry in the coming years and decades. FEV aerospace’s portfolio is therefore primarily focused on the development of sustainable propulsion solutions. In addition to fuel cells with green hydrogen and Sustainable Aviation Fuels (SAF), the focus is on further electric powertrains, battery technologies and corresponding recycling concepts. The portfolio is rounded off by software solutions, particularly in the fields of systems engineering and cyber security.

FEV first participated in aviation development projects in the early 1980s and has been continuously active in the aerospace segment ever since. The company draws back on its automotive experience and adapts this know-how to aerospace applications.

The brand launch at ILA Berlin is no coincidence. “The exhibition focuses on the future of aviation and space,” said Dr. Christian Eschmann, Director Aerospace at FEV. “Our focus on innovation, new technologies and sustainability is fully in line with the trade show.”

Eschmann is excited about the challenges ahead: “The implementation of FEV aerospace is a clear commitment to the company’s focus on the aviation and space industry segment. With our expertise in engineering, supported by our know-how in consulting and testing, we are ideally equipped for the challenges ahead.”

Journalists and aviation enthusiasts can get to know FEV aerospace at ILA in hall 2, booth 312. Here, the company will be presenting the demonstrator of a 4-cylinder boxer engine for small aircraft that has been converted to run purely on hydrogen, as well as the “Breeze” fuel cell.

About FEV

FEV has always pushed the limits.
FEV is a globally leading engineering provider in the automotive industry and internationally recognized leader of innovation across different sectors and industries. Professor Franz Pischinger laid the foundations by combining his background in academia and engineering with a great vision for continual progress. The company has supplied solutions and strategy consulting to the world’s largest automotive OEMs and has supported customers through the entire transportation and mobility ecosystem.

As the world continues to evolve, so does FEV.
That’s why FEV is unleashing its technological and strategic expertise into other areas, applying its forward thinking to the aerospace and energy sectors. Thanks to its software and system expertise, the company also leads the way making intelligent solutions available to everyone. FEV brings together the brightest minds from different backgrounds and specialties to find new solutions for both current and future challenges.

But FEV won’t stop there.
Looking ahead, FEV continues to push the limits of innovation. With its highly qualified >7,100 employees at more than 40 locations globally, FEV imagines solutions that don’t just meet today’s needs but tomorrow’s. Ultimately, FEV keeps evolving – to a better, cleaner future built on sustainable mobility, energy and software that drives everything. For the company’s partners, its people and the world.

#FeelEVolution

Aachen, Germany, May 2024 – FEV is a leading global development service provider that specializes in sustainable mobility, energy and software solutions. In this context, the technology-open company can also draw on many years of experience in the field of sustainable fuels. As a technical partner, FEV will supply the outfit of Bonk Motorsport with renewable fuel, thus supporting the team’s commitment to sustainability. At the prestigious Nürburgring 24-hours race, the team’s BMW M4 GT4 will compete in the highly acclaimed class for vehicles powered by alternative fuels.

“We are thrilled to partner with team Bonk Motorsport, which has already repeatedly proven its excellent reputation in the racing scene with numerous titles in the touring car and GT sector,” said Dr. Johannes Scharf, Chairman of the Executive Board, FEV Europe. “For us, the team is also the perfect partner in the area of sustainability thanks to its endeavors to achieve the best results. After all, end consumers always benefit from the knowledge gained in motorsport when it is transferred to series production vehicles.”

“With FEV, we have gained a strong partner who, as a technological innovation leader, meets our extreme demands in motorsport and demonstrates a high level of expertise in the field of renewable fuels. This helps us to give racing and mobility as a whole a future through sustainable acting,” said Michael Bonk, Managing Director of Bonk Motorsport.

The renewable ‘eFuel Racing 98’ supplied by FEV is produced by DeCarTrans, a consortium coordinated by FEV which is being funded by the German Federal Ministry of Transport and Digital Infrastructure (BMDV). It is the largest project ever funded by the BMDV. The constantly growing consortium currently comprises 15 partners from research, the process engineering and mineral oil industries as well as renowned OEMs. Their goal is to further develop an innovative process to produce synthetic gasoline from methanol, which is produced from biogenic or regenerative sources.

In May, the M4 GT4 of renowned BMW customer sports team Bonk Motorsport completed its first tests using renewable ‘eFuel Racing 98’ on team partner Bertrandt’s test bench. The test runs were carried out in direct comparison with conventional fuel. The initial results showed that the use of renewable fuels is reliably possible even without technical modifications to the vehicle and that the performance data is comparable to that of conventional fuel. In addition, the analyses showed that the number and mass of particles emitted could be reduced by around half compared to conventional fuel. During the production of renewable fuels, the same amount of CO₂ is extracted from the atmosphere as the vehicle emits during operation. Hence, racing the Bonk-BMW on the notorious Nürburgring-Nordschleife in the 24-hours race is completely CO₂-neutral from a well-to-wheel perspective.

“We are not surprised by the latest results. They confirm the fact that renewable fuels and future e-fuels are an important enabler to achieve the climate targets by 2035,” said Dr. Raul Tharmakulasingam, Project Manager Gasoline Powertrains at FEV and project manager of DeCarTrans.

By using renewable fuels, the existing fleet of vehicles with combustion engines can be operated in a directly climate-neutral manner and the transition of mobility can be accelerated, “at the same time as the expansion of electromobility and in parallel with the various important hydrogen applications,” said Tharmakulasingam.

The use of ‘eFuel Racing 98’ from FEV and DeCarTrans under race conditions in the 550 hp Bonk Motorsport BMW M4 GT4 can be experienced during the Nürburgring 24-hours race on June 1 – 2, 2024. Drivers will be Nordschleife experts Michael Schrey, Jörg Weidinger and Martin Kroll.

About FEV

FEV has always pushed the limits.
FEV is a globally leading engineering provider in the automotive industry and internationally recognized leader of innovation across different sectors and industries. Professor Franz Pischinger laid the foundations by combining his background in academia and engineering with a great vision for continual progress. The company has supplied solutions and strategy consulting to the world’s largest automotive OEMs and has supported customers through the entire transportation and mobility ecosystem.

As the world continues to evolve, so does FEV.
That’s why FEV is unleashing its technological and strategic expertise into other areas, applying its forward thinking to the aerospace and energy sectors. Thanks to its software and system expertise, the company also leads the way making intelligent solutions available to everyone. FEV brings together the brightest minds from different backgrounds and specialties to find new solutions for both current and future challenges.

But FEV won’t stop there.
Looking ahead, FEV continues to push the limits of innovation. With its highly qualified >7,100 employees at more than 40 locations globally, FEV imagines solutions that don’t just meet today’s needs but tomorrow’s. Ultimately, FEV keeps evolving – to a better, cleaner future built on sustainable mobility, energy and software that drives everything. For the company’s partners, its people and the world.

#FeelEVolution

Aachen, May 2024 – FEV Consulting, the management consulting firm of FEV Group, was recognized with the Sustainability Award in Automotive 2024 for the development of “CycleBat” mid-May. The innovative solution enables manufacturers of electric vehicles to accurately predict the cost of recycling and the environmental impact of their batteries. The award was presented by the ATZ/MTZ Group and management consultants Arthur D. Little at the 18th International MTZ Congress on Future Powertrains in Chemnitz on May 15, 2024.

Recycling will play an essential role in optimizing the ecological footprint of battery cells for electric vehicles in the future. However, very few manufacturers have so far considered the costs associated with extended producer responsibility (EPR) when designing cells or calculating lifecycle costs.

Focus on ecological and economic implications

“FEV Consulting has developed ‘CycleBat’, the latest tool for the sustainable transformation of electric vehicles. It enables OEMs to quantify and justify the positive effect of ‘design for recycling’ measures when designing new batteries,” said Alexander Nase, Managing Director of FEV Consulting. “Without this quantitative evaluation of ‘design for recycling’, these measures are currently impossible to implement with regard to costs and performance constraints.”

The “CycleBat” model, which has been developed and validated together with industry partners from the entire battery value chain, takes into account the entire life cycle of a vehicle battery, with a particular focus on the end of life. Starting with recycling technologies and the development of a corresponding ecosystem and the consideration of economies of scale, “CycleBat” can be used to model the entire costs and make the ecological footprint of battery recycling visible. This is compared with the corresponding market potential. “CycleBat” is based on FEV Consulting’s extensive knowledge and experience on both the manufacturer and the market side. The parameters can be adapted to the respective customer.

Alexander Nase is certain: “Lower costs and improved material recovery will make battery recycling competitive. In the future, manufacturers will even be able to sell discarded batteries to increase their value instead of having to pay disposal fees.”

Comprehensive portfolio for the development of sustainable propulsion technology

FEV presented its expertise and portfolio for the climate-neutral mobility of the future at the MTZ Congress in Chemnitz on May 14 and 15. Dr. Norbert W. Alt, COO of FEV and member of the conference advisory board, chaired the session “Renewable energy sources and charging technology”. A current example of FEV’s innovative spirit is the efficient and cost-saving electric dual-rotor drive developed jointly with the Munich-based start-up DeepDrive, which the two companies presented to an interested audience. In the “Charging” session, FEV also presented the “Techno-economical sizing of local energy systems applied to a fast-charging hub in Germany” and in the “Fuel Cell” session the “Aging for Optimal System Design in Fuel Cell Heavy-Duty Trucks”.

About FEV

FEV has always pushed the limits.
FEV is a globally leading engineering provider in the automotive industry and internationally recognized leader of innovation across different sectors and industries. Professor Franz Pischinger laid the foundations by combining his background in academia and engineering with a great vision for continual progress. The company has supplied solutions and strategy consulting to the world’s largest automotive OEMs and has supported customers through the entire transportation and mobility ecosystem.

As the world continues to evolve, so does FEV.
That’s why FEV is unleashing its technological and strategic expertise into other areas, applying its forward thinking to the aerospace and energy sectors. Thanks to its software and system expertise, the company also leads the way making intelligent solutions available to everyone. FEV brings together the brightest minds from different backgrounds and specialties to find new solutions for both current and future challenges.

But FEV won’t stop there.
Looking ahead, FEV continues to push the limits of innovation. With its highly qualified >7,100 employees at more than 40 locations globally, FEV imagines solutions that don’t just meet today’s needs but tomorrow’s. Ultimately, FEV keeps evolving – to a better, cleaner future built on sustainable mobility, energy and software that drives everything. For the company’s partners, its people and the world.

#FeelEVolution

Aachen, March 2024 – As a leading global development service provider, FEV stands for sustainable innovations and technologies in the fields of mobility, energy, and software. For more than four decades, the company has provided society with a wide range of mobility and energy solutions that have made everyday life and the way we move more climate-friendly, efficient, and safe. A further commitment to a clean future recently followed with the signing of the Aachen Climate City Contract by the management of FEV Europe GmbH. The company, which has its headquarters in Aachen, Germany, is thus committed to supporting the city in achieving climate neutrality by 2030. The agreement is part of the EU’s “100 Climate-Neutral and Smart Cities by 2030” mission, for which the city of Aachen was selected as an innovation hub.

“Responsible behavior is in our corporate DNA,” said Dr. Johannes Scharf, Chairman of the Executive Board, FEV Europe GmbH. “At the same time, we have become known worldwide as a technological pioneer with sustainable innovations since our foundation. Signing the Climate City Contract is therefore a logical consequence of leading by example and making an important contribution to the climate neutrality of the city of Aachen.”

The contract includes FEV’s voluntary commitment to be climate-neutral by 2030, which means achieving a balance between carbon emissions and the absorption of carbon from the atmosphere. The company is providing the city with a climate strategy and action plan to show which solutions will be used to achieve this goal in the coming years.

This includes the installation of a photovoltaic system at the company’s Neuenhofstraße site with a total annual output of over 1 GWh by the end of 2026, which is currently being planned. This measure alone will save FEV over 500 tons of CO₂ at the Aachen site every year. Further measures are currently being discussed within the company and examined regarding their best possible feasibility.

In addition to its direct involvement in the Aachen Climate City Contract, the engineering service provider is also contributing to cleaner cities with the solutions it offers – far beyond the borders of Aachen. FEV has been developing clean and efficient drive systems and offering advanced solutions for a wide range of technologies since the company was founded in 1978. “Thanks to our technological openness and the holistic approach that we pursue at FEV, we develop solutions along the entire value chain,” said Scharf. “This includes measures for infrastructural challenges such as hydrogen as well as the production of alternative fuels with sustainable energies or batteries with ecologically compatible components.”

About FEV

FEV has always pushed the limits.
FEV is a globally leading engineering provider in the automotive industry and internationally recognized leader of innovation across different sectors and industries. Professor Franz Pischinger laid the foundations by combining his background in academia and engineering with a great vision for continual progress. The company has supplied solutions and strategy consulting to the world’s largest automotive OEMs and has supported customers through the entire transportation and mobility ecosystem.

As the world continues to evolve, so does FEV.
That’s why FEV is unleashing its technological and strategic expertise into other areas, applying its forward thinking to the aerospace and energy sectors. Thanks to its software and system expertise, the company also leads the way making intelligent solutions available to everyone. FEV brings together the brightest minds from different backgrounds and specialties to find new solutions for both current and future challenges.

But FEV won’t stop there.
Looking ahead, FEV continues to push the limits of innovation. With its highly qualified >7,100 employees at more than 40 locations globally, FEV imagines solutions that don’t just meet today’s needs but tomorrow’s. Ultimately, FEV keeps evolving – to a better, cleaner future built on sustainable mobility, energy and software that drives everything. For the company’s partners, its people and the world.

#FeelEVolution

Aachen, March 2024 – FEV, a leading global engineering service provider and innovation leader for sustainable mobility and energy solutions, has developed PD-HVX (Partial Discharge – High Voltage X), the world’s first solution for early detection and prevention of partial discharge (PD) in high-voltage electric drive units (EDUs). PD can cause damage to the insulation in modern EDUs, which in the worst-case scenario can result in a total failure of the vehicle. FEVs PD-HVX uses well established measuring systems with specialized sensors, which are used in EDUs for qualitative measurement. This enables customers to identify partial discharge during the development phase and take the necessary action.

PD is a local electrical sparkover that can occur at high voltages above 600 volts. It is caused by extremely small defects or inhomogeneities in the insulation material or soiled surfaces. If it remains unnoticed within an EDU and occurs repeatedly, PD leads to gradual damage of the insulation and to a premature stop of the vehicle.

PD-HVX uses electromagnetic frequency analysis, one of the most precise and reliable measurement methods for the application field of electrical propulsion systems, to measure the electromagnetic fields around the drive unit to be analyzed. The innovative software then uses the measurement results to determine whether partial discharge occurs within the EDU during operation.

“PD has been known for a long time in the field of electrical systems engineering and high-voltage transmission networks, where corresponding tests are common practice,” said Dr. Michael Stapelbroek, Vice President Electric Powertrain at FEV. “In the automotive sector, however, the phenomenon is just gaining focus with the increasing spread of 800-volt batteries. Thanks to our many years of expertise in the development of EDUs, with PD-HVX we can now offer our customers a dedicated solution for PD.”

This solution consists of a comprehensive service package for vehicle OEMs and suppliers. The test equipment, which is optimized for EDU operation, filters out drive-related interference signals and therefore enables significantly better measurement results for PD. The customer subsequently receives the data obtained in the tests for evaluation and further interpretation.

FEV has many years of experience in power, propulsion, and control electronics as well as various areas of sensor technology in vehicle construction. On request, the customer can also make use of this expertise in data analysis and system optimization.

“By detecting partial discharge in the EDU at an early stage, possible reasons for insulation damage in the electronics can be eliminated during the development process. This prevents delays due to premature vehicle failures and additional costs during development,” said Stapelbroek, summarizing the advantages of the solution.

For further information about PD-HVX please visit www.fev.com/partialdischarge

About FEV

FEV has always pushed the limits.
FEV is a globally leading engineering provider in the automotive industry and internationally recognized leader of innovation across different sectors and industries. Professor Franz Pischinger laid the foundations by combining his background in academia and engineering with a great vision for continual progress. The company has supplied solutions and strategy consulting to the world’s largest automotive OEMs and has supported customers through the entire transportation and mobility ecosystem.

As the world continues to evolve, so does FEV.
That’s why FEV is unleashing its technological and strategic expertise into other areas, applying its forward thinking to the aerospace and energy sectors. Thanks to its software and system expertise, the company also leads the way making intelligent solutions available to everyone. FEV brings together the brightest minds from different backgrounds and specialties to find new solutions for both current and future challenges.

But FEV won’t stop there.
Looking ahead, FEV continues to push the limits of innovation. With its highly qualified >7,100 employees at more than 40 locations globally, FEV imagines solutions that don’t just meet today’s needs but tomorrow’s. Ultimately, FEV keeps evolving – to a better, cleaner future built on sustainable mobility, energy and software that drives everything. For the company’s partners, its people and the world.

#FeelEVolution

Aachen, February 2024 – The research project “Methanol Standard”, coordinated by FEV, has been successfully completed. The focus of the project was to investigate the technical fundamentals needed for the European standardization of methanol as a fuel. The results demonstrate that sustainably produced methanol constitutes a promising CO₂-neutral alternative to fossil fuels in future mobility. The objective is to promote fuel diversification and reduce life-cycle emissions to almost zero. In this evolutionary process, Germany is supposed to pave the way as a role model and develop a standard that can subsequently be applied all over Europe.

FEV contributed its long-standing experience and expertise as a globally leading engineering service provider for the transportation and energy sectors to the project. This included three-dimensional computational fluid dynamics (CFD) simulations as well as the development of an adapted control technology for a single-cylinder engine used in the project. In addition, FEV provided support in the area of complete vehicle tests by conducting cold start examinations. It was possible to prove that the engine of one of the project partners, which was operated with methanol, was still capable of starting at low temperatures.

“The surveyed data provides valuable insights into the technical feasibility and the necessary subsequent evolutionary steps,” said Dr. Thorsten Schnorbus, Director Business Development at FEV energy. “Together with our partners, we have investigated the compatibility of methanol with existing technologies and fuel standards and identified potential areas for further research and development activities. These include suitable additives for improving lubrication and combustion properties, or the use of methanol in fuel cells,” said Dr. Schnorbus, summarizing the key findings of the study.

Another important finding of the investigations: from a technical point of view, existing injection systems can already be operated with methanol, but there is a need for development at the high injection pressures currently in use. Methanol can be mixed with conventional fuels at 15 percent as an additive (M15) but can also be used in pure form at 100 percent (M100).

“Methanol Standard” comprised a total of 17 research centers and associated partners. In addition to universities, research institutes, small and medium-sized enterprises, these also included globally active companies and well-known manufacturers from the automotive and commercial vehicle industries.

In parallel with the European research activities, the application of methanol with its high potential for reducing CO₂ emissions is also being driven forward in large test fleets in China. To increase the visibility of this development and highlight the opportunities for methanol as an energy source and fuel, a standardization group for M100 has been set up based on the findings.

The power-to-liquid technologies required for the sustainable generation of methanol have already reached a very high level of maturity and will be available on the market in the nearby future. Using hydrogen produced from renewable sources, these plants convert CO₂, for example from biological waste products, into methanol. Pilot plants for this technology are in operation in Iceland, the Netherlands, northern Germany and Chile, among others, already contributing to the climate-neutral production of sustainable fuels.

From FEV perspective, the application fields for sustainable fuels vary in terms of their potential. “We rate the benefits in maritime propulsion, large construction or agricultural machinery, and locomotives very highly globally,” said Dr. Schnorbus. “For passenger cars and smaller machines, on the other hand, we see their potential in Europe more in special applications.”

The involvement of FEV as coordinator of “Methanol Standard” is another example of the company’s commitment to developing sustainable fuels. Last year, the first 15,000 liters of renewable fuel based on green methanol were produced in Freiberg, Saxony (Germany), as part of the “DeCarTrans” project, also led by FEV.

About FEV

FEV has always pushed the limits.
FEV is a globally leading engineering provider in the automotive industry and internationally recognized leader of innovation across different sectors and industries. Professor Franz Pischinger laid the foundations by combining his background in academia and engineering with a great vision for continual progress. The company has supplied solutions and strategy consulting to the world’s largest automotive OEMs and has supported customers through the entire transportation and mobility ecosystem.

As the world continues to evolve, so does FEV.
That’s why FEV is unleashing its technological and strategic expertise into other areas, applying its forward thinking to the aerospace and energy sectors. Thanks to its software and system expertise, the company also leads the way making intelligent solutions available to everyone. FEV brings together the brightest minds from different backgrounds and specialties to find new solutions for both current and future challenges.

But FEV won’t stop there.
Looking ahead, FEV continues to push the limits of innovation. With its highly qualified >7,100 employees at more than 40 locations globally, FEV imagines solutions that don’t just meet today’s needs but tomorrow’s. Ultimately, FEV keeps evolving – to a better, cleaner future built on sustainable mobility, energy and software that drives everything. For the company’s partners, its people and the world.

#FeelEVolution

Aachen, Germany, January 2024 – Effective 1 January, Mayank Agochiya assumed the role of president of FEV Asia. In this capacity, Mayank joins the global management board of FEV, a leading global innovation driver in the mobility, energy and software development sectors.

Mayank, who has more than two decades of experience in engineering and strategic consulting in various roles in Asia, Europe and North America, joined FEV in 2016. Prior to his appointment as president of FEV Asia, he served as managing director of FEV Consulting in the U.S., where he successfully drove the company’s expansion. He will continue to hold this role on an interim basis.

Mayank began his career as a calibration engineer in India and Japan. He also held various management positions in in Korea, China and Turkey. In his new position, he succeeds Ulrich Pfahl, who left FEV at his own request.
“We are pleased to have found the ideal candidate for the position of the president of FEV Asia in Mayank Agochiya. In addition to his professional expertise, he is very familiar with the different markets and cultures in the Asian region,” said Patrick Hupperich, president and CEO of FEV Group. “At the same time, we would like to thank Ulrich Pfahl for the trusted and successful collaboration over the past six years.”

About FEV

FEV has always pushed the limits.
FEV is a globally leading engineering provider in the automotive industry and internationally recognized leader of innovation across different sectors and industries. Professor Franz Pischinger laid the foundations by combining his background in academia and engineering with a great vision for continual progress. The company has supplied solutions and strategy consulting to the world’s largest automotive OEMs and has supported customers through the entire transportation and mobility ecosystem.

As the world continues to evolve, so does FEV.
That’s why FEV is unleashing its technological and strategic expertise into other areas, applying its forward thinking to the aerospace and energy sectors. Thanks to its software and system expertise, the company also leads the way making intelligent solutions available to everyone. FEV brings together the brightest minds from different backgrounds and specialties to find new solutions for both current and future challenges.

But FEV won’t stop there.
Looking ahead, FEV continues to push the limits of innovation. With its highly qualified >7,100 employees at more than 40 locations globally, FEV imagines solutions that don’t just meet today’s needs but tomorrow’s. Ultimately, FEV keeps evolving – to a better, cleaner future built on sustainable mobility, energy and software that drives everything. For the company’s partners, its people and the world.

#FeelEVolution