Case Study #1
Hybrid Commercial Vehicle

MWW1 was contracted to design, fabricate & install the complete fuel system for a “range extended” gasoline hybrid electric vehicle.

• Concept design, outline all critical components, layout connectivity, and controls architecture / functionality
• Design & integrate all fuel system hardware into existing vehicle
• Conduct DFMEA, ensure component & system level compliance for certification; update design as necessary & repeat process
• Create full drawing stack for components as well as system level integration documentation.
• Fabricate & install all components into prototype vehicle

Case Study #2
Emerging Marker Commercial Vehicle

MWW1 was contracted to program manage the “clean sheet” design & development of multispeed automatic transmission; as well as design, fabricate & install all necessary hardware to integrate transmission to prototype vehicle.

• Oversaw concept architecture refinement & packaging assessment / modification
• Created and managed project budget & timeline, project milestones & deliverables
• Lead DFMEA efforts at the transmission (component) and vehicle integration levels
• Designed & Fabricated custom valve body test stand for mechanical & controls development
• Machined various components internal to the prototype transmission
• Designed & fabricated electrical wiring harness for transmission spin rig testing
• Designed & fabricated transmission vehicle mounts, driveshaft connectivity, shift cabling & bracketry, transmission electronic control unit & data acquisition housings, mounting, and all associated electrical wiring.

Case Study #3
Performance Electric Vehicle

MWW1 was contracted to conduct Design Release Engineering services for the Fisker Karma Powertrain which included the Engine / Generator set (Gen Set) & Rear Drive Module (RDM).
• Program manage production intent RDM development work scope with customer, transmission design supplier, production transmission manufacturer & vehicle final assembly manufacturer
• Perform DFMEA activities related to vehicle torque security & ASIL 26262
• Integrate Gen Set & RDM mechanical, electrical, fluid & CAN Bus systems within overall vehicle architecture, ensure overall system integrity
• Create vehicle & component level performance specifications & requirements
• Create Gen Set & RDM component & system level testing requirements
• Create RDM inspection & rebuild instructions for early production units