Electrical systems, electronics and software for complete machine functionality.

• Electrical/electronic component selection
• Cable selection and sizing
• Power distribution and fuse selection
• Vehicle electrical schematics
• Harness design
• 3D cable/harness routing in mechanical CAD
• 2D flattened harness drawings
• Bills of materials and procurement/prototype/production drawings
• Zuken-to-MCAD routing integration using XML reports
• Integration of engine, transmission, spreader and other controllers, displays and load-moment systems
• Prototype-build support and field validation
• Fuse-state checks in Zuken E3
• Voltage-drop checks
• Circuit-current checks

Machine software and HMI

• Requirements definition, analysis and review
• Software requirement documents and statements of requirements
• Embedded software for diesel and electric machines
• Vehicle-management, drivetrain and application ECU software
• Display/HMI applications
• Manual and automatic machine-function control
• Upgrades and migration to replacement displays
• Machine ECU integration with battery-management systems and inverters
• HMI button/touch-event handling over CAN
• Hydraulic pump-control applications
• Machine power management
• Software improvements and legacy-code analysis

Embedded architecture

• Real-time embedded architectures
• Drivers and protocols
• Gateways
• Integration and protocol verification
• Embedded C for 8/16/32-bit microcontrollers and DSPs
• Verilog HDL for FPGAs

• Control-algorithm modelling
• PID controller design
• Reconstruction of models from legacy code
• Simulation
• Deployment to target hardware
• Script generation
• CAN 2.0 and J1939
• Model-in-the-loop (MIL), code coverage, Model Advisor checks and requirements traceability
• Software-in-the-loop (SIL)
• Hardware-in-the-loop (HIL)

Verification and validation

• Embedded software, firmware and product verification
• Test plans, cases and execution plans
• Functional, integration and regression testing
• Debugging, code/functional coverage and results analysis
• Bug reporting and test reports
• Hardware setup and software loading
• Bench, HIL and full-machine validation
• Test automation
• Remote HMI verification

Diagnostics

• CAN traffic monitoring and log analysis
• Stored-data diagnostics
• Device/machine reprogramming
• Ongoing test-plan updates
• Protocol compliance and real-time/critical-timing failure testing

• Multilayer boards
• Footprint libraries
• Schematic capture
• PCB layout and routing
• EMI/EMC mitigation
• Gerber files, BOMs and version-controlled assembly drawings
• CISPR 25 Class 5 compliance work

• Low-voltage switchgear and motor control centres
• PLC/HMI selection
• Ladder logic and HMI programming
• Low-voltage motor-control design/testing
• Terminal-block and component arrangement in control panels
• Cable routing and integration
• Compliance testing
• Short-circuit current rating (SCCR) coordination studies

Plant layout and manufacturing engineering: Prototyping, testing and manufacturing engineering→

System specification and integration

• Battery options: lead-acid, LFP and NMC
• Battery management systems
• Thermal management
• Charging
• Traction motors and gearboxes
• Implement-pump motor drives
• Motor controllers
• Inverters
• Regenerative braking
• Machine controllers
• HMI

Development and validation

• Battery-electric machine ECU and HMI development
• System integration
• Bench verification
• Vehicle validation

KSD supports system selection, specification and integration. Mechanical packaging and feasibility: Electrification: mechanical and whole-machine contribution→