Emission-free mobility in the commercial vehicle market is no longer a distant utopia. Driven by increasing demand, stricter regulatory requirements and the pressure for technological solutions to halt climate change, OEMs also have to offer alternative drive systems such as electric commercial vehicles as quickly as possible. With our in-depth technological expertise in the field of e-mobility, we offer numerous components specifically for electric trucks, buses and other commercial vehicles.
The transformation to electric drives is not stopping at commercial vehicles. Our decades of industry-specific experience in architecture and electronics for commercial vehicles enable us to drive the development of e-vehicle electronics forward together with our customers.
Discover our solutions for electric commercial vehicles
Components for comprehensive e-vehicle electronics
Architecture and consulting
AUMOVIO as your one-stop partner for E-Mobility
AUMOVIO supports customers across the entire development lifecycle of electric heavy-duty vehicles – from the initial concept to industrialization and series production. As a one-stop-shop partner, AUMOVIO combines deep expertise in system architecture, engineering, software, vehicle integration, and validation under one roof.
With a holistic and structured approach, AUMOVIO covers concept development, system and software engineering, vehicle integration, testing, homologation, and market launch. This end-to-end capability reduces complexity, accelerates development, and ensures reliable, scalable, and future-proof e-mobility solutions for heavy-duty vehicles.
Software
From architecture to series production
AUMOVIO provides a comprehensive portfolio of automotive software services that supports customers throughout the entire product lifecycle – from software architecture and application development to industrialization and production support. Our scalable service model allows customers to focus on their core application development, while AUMOVIO takes care of base software, integration complexity, and system readiness.
With deep expertise in AUTOSAR, functional safety, cyber security, and model-based development, AUMOVIO masters the challenges of modern ECU software and system integration. Supported by strong automotive partners and proven frameworks, we accelerate time-to-market and enable reliable, production-ready software solutions for e-mobility, driveline, body, and chassis applications.
Products
Electric Vehicle Communication Controller (EVCC)
The Electric Vehicle Communication Controller (EVCC) is a generic 12 V/24 V unit for use in fully-electric light, medium and heavy trucks, solo and articulated buses. As main communication controller, it is the logic gateway between the EVSE and the vehicle to recharge the high-voltage battery, initiating and monitoring the charging process. It can handle all relevant charging standards depending oncustomer requirements:
- AC/DC charging (CCS1 / CCS2 / NACS) for Europe (EU) & North America (NA).
- MCS or separate pantograph charging capability
- CHAdeMO 2.0 / GB/T upon specific customer request
- The Controller will be built and delivered as standard unit (CCS) or in a separate versionwith Ethernet (MCS) or Wi-Fi (Pantograph) functionality realized on same PCB.
- The HW & SW are developed by Aumovio. Production done in Aumovio plants.
- Hardware design supports functional safety up to ASIL-B
- Connectors: HDSCS 2 x 18pins
- Separate connectors enable variant adaptation to vehicle periphery.
- Dedicated single Ethernet PHY for MCS functionality.
- IFX TC3xx controller in LQFP-176 package.
- Multiple I/O interfaces support EU, North American, and Asian market requirements.
- Multiple CAN-FD interfaces and LED driver for the charging inlet.
- Supports Wake-up CAN, Control Pilot (CP), Proximity Pilot (PP), and Charge-Stop button.
- Supports LIN communication.
- Housing IP rating up to IP6K9K.
- Mounting in cabin, frame, or roof (bus applications).
- Supports multiple separate charging inlets (e.g., left and right) via multiple devices.
- Dimensions (mm): 140x125x47 w/o connectors plugged Weight (g): 360
- J1939 compliant CAN Communication
Bi-directional DC/DC converter (12V/24V/48V) for electric commercial vehicles
The higher power demands for components embedded in electric commercial vehicles lead to new on-board network architectures consisting of various different board nets, making bi-directional DC/DC converters necessary to bridge these board nets. Their variable design allows power delivery of up to 3.5 kW in buck and 1 kW in boost mode and is an air-cooled, cost-efficient and reliable solution for transferring energy between board nets with state-of-the-art cyber security.
- The system supports 12 V operation with an unlimited voltage range of 9 to 16 V, as well as limited operation from 6 to 9 V and 16 to 18 V.
- In 24 V operation, the system operates without limitations between 16 and 32 V and with limitations between 8 and 16 V and 32 to 36 V.
- The device has three M8 power connectors for CL40, CL30, and CL31. A 12-pin logic connector for P-CAN H, P-CAN L, and CL15 is integrated.
- The software is based on the EB-AUTOSAR platform on a dual-core microcontroller.
- UDS and J1939 protocols, as well as safety functions, are supported.
- A secure debug interface is provided.
- The system meets ASIL-B requirements.
- Functional safety.
- Integrated cybersecurity protects against unauthorized access.
- The housing is protected according to IP67 and IP6K9K standards when connectors are attached.
- Depending on the model, dimensions of 299 × 169 × 64 mm or 234 × 169 × 64 mm are available.
- The weight ranges from 1.6 to 2.6 kg, depending on the model.
Intelligent Battery Sensor (IBS)
The shunt-type IBS delivers continuous, real-time insight into the condition of conventional 12-volt lead-acid batteries by monitoring critical parameters such as state of charge, power capability, and battery health. Designed to ensure the reliable and efficient operation of modern start-stop systems, the sensor helps optimize vehicle performance and extend battery life. Mounted directly onto the battery, the IBS integrates seamlessly into the space around the negative terminal for a compact and robust installation.
- Measures battery voltage in a wide range from 5 V to 18 V for precise condition monitoring.
- Supports bidirectional current measurement from –1500 A to +1500 A for accurate power analysis.
- Handles continuous currents of up to ±200 A for 2 hours at temperatures below 85 °C.
- Delivers reliable State-of-Charge (SOC) estimation with 10 % accuracy.
- Provides State-of-Health (SOH) assessment with 10 % accuracy.
- Enables State-of-Function (SOF) determination with an accuracy of 500 mV.
- Operates reliably across a wide temperature range from –40 °C to +105 °C.
- Communicates via LIN for seamless integration into vehicle networks.
- Supports CO₂ reduction strategies, including intelligent alternator control and start-stop functionality.
- Provides early battery condition warnings to help prevent unexpected vehicle breakdowns.
- Supplies comprehensive battery status information, including SOC, SOH, and SOF, in real time.
High voltage Current Sensor Module (CSM)
AUMOVIO has developed a shunt-based current sensor for automotive high-voltage battery applications in hybrid and battery electric vehicles. The sensor provides independent measurements of current, voltage, and insulation status to the Battery Management System. The Current Sensor Module (CSM) communicates via a CAN interface.
- The sensor supports high-voltage systems at 400 V and 800 V for next-generation electric and hybrid vehicles.
- It measures currents up to ±2000 A with an accuracy of ±1.0% for precise and reliable power monitoring.
- High-precision, safety-relevant current measurement enables secure operation in critical vehicle systems.
- The ambient temperature range from -40 °C to +85 °C ensures dependable performance in demanding environments.
- Optional voltage measurement provides an accuracy of ±1.5% for enhanced system insight.
- Integrated temperature measurement covers a range from -40 °C to +125 °C for complete battery monitoring.
- The compact design with an integrated bus bar allows easy and space-saving installation.
- Galvanic separation between high-voltage and low-voltage domains enhances system safety.
- High-speed measurement capability enables rapid BMS response, such as fast battery cut-off.
- The system supports functional safety up to ASIL D at the system level using shunt or magnetic current sensing.
Thermal input/output ECU
Like all EVs, electric commercial vehicles have high requirements when it comes to thermal management, e.g. active cooling and heating to keep the battery in the optimal range for maximum performance. The Thermal Input/Output ECU ensures sensor data availability by receiving and processing data from the connected sensors and actuators and providing output signals to other ECUs on the Auxiliary CAN. It also provides control interfaces to the connected sensors/ actuators via signal interfaces on the Auxiliary CAN. The Thermal input/output ECU acts as an intelligent gateway ECU and contains software to fulfill the standard diagnostic and network requirements to process signals and execute OEM in-house functions.
- The vehicle is a fully electric long-haul truck available as a tractor unit or rigid truck.
- Communication is via a CAN FD interface.
- The operating temperature range is between -40 °C and +105 °C.
- The system is designed to IP6K9K protection class.
- Functional safety complies with ASIL-B.
Acoustic Vehicle Alerting System (AVAS)
The Acoustic Vehicle Alerting System (AVAS) is a mandatory safety solution for electric and hybrid vehicles that generates a synthetic, speed-dependent driving sound to protect pedestrians and other road users by clearly signaling the presence of otherwise silent vehicles. The system features a central ECU and one actuator in the basic configuration, or up to five actuators in the premium version, enabling flexible installation on virtually any exterior body structure.
Thanks to its innovative product design, AVAS delivers extra-wide sound radiation through surface excitation, ensuring excellent audibility in all directions. Its compact size and low weight allow for seamless integration into a wide range of vehicle architectures, while the robust construction offers superior resistance to water, dust, and mechanical shock compared to conventional loudspeakers.
Key benefits of actuated sound
- Enables new design possibilities with a completely invisible sound solution.
- Delivers a natural, high-quality driving sound for enhanced pedestrian awareness.
- Reduces system complexity with fewer channels and components.
- Offers a scalable system architecture for basic to premium configurations.
- Minimizes installation space with lower volume and weight.
- Helps reduce overall system cost through efficient design.
Key benefits of ECU
- Supports both 12 V and 24 V vehicle systems with an operating range from 9 V to 32 V.
- Operates reliably in a temperature range from -40 °C to +85 °C.
- Features a high-efficiency class D amplifier with 15 W to 35 W per channel.
- Supports CAN-FD for fast and robust vehicle communication.
- Provides a minimum protection class of IP6K9K for harsh environmental conditions.
- Includes 2 MB Flash memory, with an optional upgrade to 8 MB for WAV file storage.
- Weighs approximately 250 g for lightweight system integration.
- Measures approximately 110 × 120 mm for compact installation.
Key benefits of basic transducer:
- Operates in temperatures from -40 °C to +105 °C for reliable outdoor performance.
- Delivers a power rating of 10 W (TL) and 20 W (ST) for flexible sound output.
- Covers a wide frequency range from 200 Hz to 20 kHz for natural sound reproduction.
- Provides a protection class of IP6K9K and a maximum sound pressure level above 90 dB.
- Features an impedance of 4 Ω for efficient amplifier matching.
- Weighs only 68 g, including housing, for minimal impact on vehicle weight.
- Compact dimensions of 31.8 × 56.8 × 18.6 mm enable discreet integration.
- A modular, scalable system design that covers everything from basic to premium requirements.
- Supports tuning and storage of multiple, vehicle-specific sound profiles for brand- and model-specific acoustic design.
- Requires less packaging space and offers greater flexibility for seamless vehicle integration.
- Fully compliant with global regulations, including UN R138.01 (EU, China) and FMVSS 141 (USA).
- Features an ultra-lightweight system design starting at approximately 300 g.
- Enables dynamic sound modulation via multiple CAN parameters, such as pedal position and gear selection.
Battery Management Systems (BMS)
Our Battery Management System (BMS) continuously monitors and controls the cells in the battery to ensure optimal performance, maximum efficiency, and safe operation across all driving conditions. Developed in line with state-of-the-art automotive standards, the system integrates advanced functional safety and cyber security concepts to meet the demands of modern electric and hybrid vehicles.
The BMS features powerful application software with sophisticated functions such as comprehensive diagnostics, precise State-of-Charge (SoC), State-of-Health (SoH) estimation, intelligent thermal Management and more. Built on a robust AUTOSAR basic software platform, it enables seamless integration into vehicle architectures and supports scalable, future-proof system designs.
The software concept of the 850V BMS – GEN 2 is based on a clear separation between a proven CES Battery Software Platform and individually customizable customer functions. This modular approach enables rapid integration, high operational reliability, and maximum flexibility for customer-specific and brand-differentiating applications.
- BMS
- BMS circuit boards
Battery Main Controller (BMC)
Features:
- AURIX™ TC3 microcontroller with Infineon SBC and Vector MICROSAR platform.
- Three CAN-FD interfaces, including a dedicated development interface.
- Integrated battery monitoring for voltage, current, and temperature.
- Passive insulation monitoring for high-voltage safety.
- Crash interface and support for H₂ gas sensor integration.
- Functional safety support up to ASIL-C with built-in cyber security features.
- Compact housing with IP5K0 protection (with plugged connectors).
Battery Disconnect Unit (BDU)
Features:
- Safely disconnects and protects the high-voltage battery in critical driving and crash scenarios.
- Designed for 850 V systems with 350 A continuous current and up to 1 kA peak power handling.
- Supports high inrush and cut-off currents up to 1.7 kA switch-on and 25 kA switch-off.
- Monitors voltage, current, and temperature for reliable system protection.
- Provides passive insulation monitoring for enhanced high-voltage safety.
- Meets functional safety requirements up to ASIL-C.
- Robust, compact housing with IP5K0 protection (with plugged connectors).
Cell Supervising Electronic (CSE)
Features:
- Provides precise cell voltage and temperature monitoring for optimal battery performance.
- Supports up to 18 cells per IC (max. 90 V) for a scalable battery architecture.
- Enables efficient cell balancing with up to 150 mA balancing current.
- Designed for functional safety up to ASIL-C at system level.
- Delivers reliable voltage, current, and temperature supervision.
- Compact, lightweight housing with IP5K0 protection (with plugged connectors).
- Built for long-term operation with a lifetime of up to 115,000 operating hours.
CES Responsibility
CES provides the basic software platform and core functions:
Basissoftware
- AUTOSAR-basierte Basic Software (BSW)
- Main Battery Application Software (ASW)
Battery Core Functions:
- Cell overvoltage monitoring
- Cell undervoltage monitoring
- Cell overtemperature protection
- Pack overvoltage protection
- Pack undervoltage protection
- Current limit monitoring (I²t)
- Continuous current limit supervision
- Isolation measurement
- Clamp 30c monitoring
- Interlock monitoring
- System & Control Functions
- Contactor control
- Communication with CSE
- ECU identification
- Customer ASW handler
Customer Responsibility
The customer defines and implements the vehicle-specific and brand-differentiating functions:
- State of Charge (SoC)
- State of Health (SoH)
- State of Energy (SoE)
- Operating window definition
- Operating window violation handling
- In-use histogram
- Cell balancing
48V Battery Management Systems (BMS) - low voltage
Designed for flexibility and safety, this solution supports multiple lithium-ion chemistries, including NMC, LFP, and others, making it suitable for a wide range of battery applications. It is engineered to handle 75 A continuous current and up to 150 A peak current for short durations, ensuring reliable performance under dynamic load conditions.
An integrated pre-charge circuit enables safe and controlled system start-up, while continuous monitoring of critical parameters such as voltage, current, temperature, and insulation ensures stable and secure operation at all times. Developed in compliance with ISO 26262 and supporting ASIL C, the system meets the highest automotive safety standards for safety-critical battery applications.
- Battery Management System designed for reliable monitoring and control of lithium-ion battery packs.
- Supports flexible cell configurations from 3 to 16 cells connected in series.
- Wide cell voltage range from 0.5 V to 5 V enables compatibility with various Li-ion chemistries.
- Integrated cell balancing with up to 150 mA per cell ensures optimal battery performance and longevity.
- Handles continuous charge and discharge currents up to 75 A for stable operation.
- Supports peak charge and discharge currents up to 150 A for short-duration high-load scenarios.
- Operates reliably in a temperature range from -25 °C to +60 °C.
- Designed for robust storage conditions with a temperature range from -40 °C to +85 °C.
- Communicates via CAN 2.0B for seamless integration into vehicle networks.
- Provides an external wake-up input (5–60 V) for flexible system activation.
- Precise cell voltage supervision and active balancing ensure optimal battery performance and extended lifetime.
- Continuous pack voltage and current monitoring provides reliable protection and operational stability.
- Advanced State-of-Charge (SoC) and State-of-Health (SoH) calculation, including power prediction, enables intelligent energy management.
- Designed to meet ISO 26262 requirements with functional safety support up to ASIL C.
- Cyber security–ready architecture protects battery systems against unauthorized access.
- Integrated solid-state switch enables fast, reliable, and maintenance-free switching.
- Built-in electronic fuse provides advanced protection against overcurrent events.
- Integrated pre-charge circuit ensures safe and controlled system start-up.
- Supports operation times of up to 14 seconds for high-power events.
- Integrates three temperature sensors for precise thermal monitoring.
- Handles peak currents of up to 230 A for demanding load conditions.
- Compact form factor with dimensions of 255 × 75 mm enables easy integration.
BMS – Software/Hardware features
Our Battery Management System delivers a comprehensive set of functions to ensure safe, efficient, and reliable operation of high-voltage battery systems. Covering everything from cell-level monitoring and power control to vehicle integration and functional safety, the system provides full transparency and control across the entire battery lifecycle.
With integrated features for energy management, protection, diagnostics, thermal control, and vehicle communication, the BMS seamlessly connects battery, power electronics, and vehicle systems. Designed to meet ISO 26262 safety requirements and tailored for modern electric and hybrid vehicles, it enables scalable, future-ready battery solutions for demanding automotive applications.
- SOC, SOH und Power Prediction
- Battery current sensing and monitoring
- Passive cell balancing
- Defective cell detection
- Cell connection monitoring
- Thermal management
- Control of solid-state switches
- Pre-charge control
- Fuse blow detection
- Fuse aging monitoring
- Pyro fuse firing circuit
- Pyro fuse diagnostic circuitry
- Coolant flow rate acquisition
- Coolant temperature determination
- Coolant control (fan, pump, valve)
- Fault management
- UDS diagnostics
- Vehicle communication
- ECU power management
- Wake-up management
- Supply voltage monitoring
- Thermal monitoring
- Crash signal sensing
- Cell voltage monitoring
- Cell temperature monitoring
- Pack voltage measurements
Twin Motor Control
The Twin Motor Control solution enables precise and reliable control of a wide range of electric actuators. Designed for versatile automotive applications, it supports the control of BLDC motors, DC motors, and solenoids, covering multiple use cases within modern vehicle systems.
With its flexible architecture and robust control capabilities, Twin Motor Control allows efficient actuation, smooth operation, and precise response, making it an ideal solution for advanced motion and actuator control in electric and hybrid vehicles.
- Twin motor control dimensions
- Twin motor control
- Operates reliably across a wide temperature range from –40 °C to +120 °C.
- Supports the PSI5 communication protocol for robust and high-speed data transmission.
- Designed with a high level of functional maturity for automotive applications.
- Meets functional safety requirements up to ASIL B(D).
- Based on a proven design with more than 10 years of series production experience.
- Start of Production (SOP) achievable approximately two years after nomination.
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