“We need a battery pack” is the most expensive sentence in product development. Not because the pack is hard — because the sentence hides every decision that costs money. We turn it into a spec your suppliers can quote and your certifier can accept.
Cell selection and architecture trade-offs, packaging envelope, voltage and energy targets, cost model.
Applicable regulations, test plan, lab options, timeline and budget — UN R100 / R10 / UN 38.3 / IEC 62619 / EU 2023/1542.
Cooling concept, duty-cycle loads, lifetime and SOH estimate, margin where it actually matters.
BMS-to-vehicle interface, CAN / DBC definition, fault tree and commissioning plan.
ECM parameter identification, SOC / SOH estimation — validated on an independent duty cycle, with the applicable boundary stated explicitly.
Where this design will fail in production, drawn from volume-programme experience.
Improvement in equivalent fuel consumption on a −10 °C CWTVC duty cycle (start/end SOC corrected), from a hybrid-vehicle thermal-management co-development combining system modeling, component matching and coordinated control. Published with permission.
The lesson isn’t the number — the compressors, valves and coolant loops were already there. At that stage most thermal problems aren’t component problems. They’re coordination problems.
Fixed scope, 4–8 weeks. You keep the spec; suppliers quote from it.
Violaeon is an independent battery-pack engineering practice, working with manufacturers in Europe and North America who are too small for a tier-1’s attention and too specialised for a standard pack.
Violaeon — violet + aeon. Violet is the shortest visible wavelength: the extreme of a blue shift. Engineering value is created the same way — early, before the design freezes.