Hardware & Software

Electronics development

Gerber layout of an 8-channel voltage and temperature monitoring PCB designed at KE-TEC
SECTION 01

Electronics Hardware Development

From the first idea to the finished product, we develop reliable, bespoke electronics. We combine sound technical expertise with hands-on development and a clear focus on flexibility, functionality and accuracy. Our work covers the design and development of electronic circuits, the specification and selection of suitable components, PCB design, and prototype development and commissioning.

CAD model of a KE-TEC 8-channel battery monitoring board with screw terminals, designed to fit the 3D-printed housing
SECTION 02

Software Development

Alongside the hardware we develop, we take on the low-level software and embedded development, so hardware and software are matched to each other from the start. From firmware and driver development, through the control of components and interfaces, to commissioning and optimisation, we write the software around the requirements of each system. Because hardware and software are developed hand in hand, development is fast and the result integrates flexibly into existing ecosystems.

Populated 8-channel voltage and temperature monitoring board on the KE-TEC validation bench
SECTION 03

System Integration

We integrate external devices, components and systems into our ecosystem, developing and implementing the interfaces needed for reliable communication and smooth data exchange. From connecting and configuring external hardware, through custom communication interfaces, to integration into our in-house test environment, we make sure every component works reliably together. We support common communication standards as well as customer-specific interfaces and protocols.

Battery power data plotted over time, showing charge and discharge across multiple measurement channels
SECTION 04

Data Analysis and Visualisation

To control and understand tests and analyses properly, the right visualisation is essential. Our custom-developed visualisation and evaluation software presents the data clearly, reveals correlations and makes measurement results quick to assess.

Whether it is a customer project or an internal one, our electronics team always finds a suitable, efficient solution.

From measurement to control, from small to very large: we develop electronics in-house to your requirements.

Hardware and softwareDeveloped in-house
µV to kV nA to kAA wide range of power classes
Mechanically protected3D printing or conventional manufacturing
A wide range of interfacesCAN, Modbus, Ethernet and more

How a development project works with us.

Using an example project, we show you how we develop new electronics and which process steps we can support you with.

Thought through end to end

From the first idea to the finished product, we develop reliable, tailored electronics solutions. We combine sound expertise with practical development and a clear focus on flexibility, functionality and accuracy. Our services cover the design and development of electronic circuits, the specification and selection of suitable components, PCB design, and prototype development and integration into existing environments.

  1. 01

    From PCB design to production

    We turn your idea into finished hardware. To check the feasibility and cost of a concept, we first build a circuit design. If the idea is technically feasible, the project moves on to PCB layout and the selection of the right components.

    • Implementation of customer-specific requirements
    • A broad range of requirements covered
  2. 02

    Enclosure development

    Our 3D printers let us produce a protective enclosure for any circuit board at very short notice. Where needed we use special ESD- or EMI-protected materials, to avoid not only mechanical but also electromagnetic disturbances. Built-in fans also keep operating conditions good.

    • Robust protection for the electronics (EMI & ESD)
    • Fan integration and secure mechanical enclosures possible
  3. 03

    A wide range of I/O options

    From communication over USB or CAN to controlling and monitoring devices through a web server: we build the right interface into your electronics for the best possible use and connectivity.

    • CAN, Modbus, Ethernet and more
    • Control via web server possible
    • Galvanic isolation
  4. 04

    Intensive testing and validation

    When electronics are developed for measurement or control tasks, the accuracy and reliability of the devices must be checked meticulously. With our extensive laboratory equipment and the ability to test beyond the performance limits, we can make sure the electronics meet the requirements.

    • Calibration available as an option
    • Testing up to the performance limits and into abuse testing
Past Projects

A small selection of our development projects so far

BMS control board developed in-house at KE-TEC, with microcontroller, DC/DC converters and three Ethernet ports

In-house developed BMS controlling a 1 MW storage system

With our expertise in developing battery management system electronics, we set up and operated the first MW-scale storage system in the whole of southern Germany as a pilot project back in 2014.

Thermal map of a battery cell measured with KE-TEC's flexible NTC sensor film: hottest at the tabs, with the temperature trend behind it

Advanced temperature measurement on battery cells

To measure and visualise the surface temperature of cells better during cycling tests, we developed a flexible film whose readings are shown in a live 3D view.

Aisle inside the ESS02 battery storage container, with cabled battery modules racked on both sides

Development and build of ESS02 with 1.2 MWh capacity

To stabilise the power supply for our own cycling operation, we developed a storage concept that makes the company almost energy self-sufficient. By reusing EV modules (second use), our largest self-developed storage system to date reaches 1.2 MWh.

Close-up of a populated KE-TEC electronics board with Ethernet ports
Hot-air rework on a BMS board at the KE-TEC precision assembly bench
Inspection of a circuit board under the stereo microscope at KE-TEC
Q&A

Straight answers, before you write to us

Are hardware and software developed together and matched to each other?

Developing hardware together with its software is one of our greatest strengths, because everything is developed in-house and all the expertise is here on site. Not only the embedded software but also the control and visualisation solutions are matched to the hardware.

Can you analyse existing hardware and fix faults?

With our exceptionally well-equipped test laboratory, we can support your troubleshooting with technologies such as computed tomography and laser and scanning electron microscopy. Once the cause is found, we are glad to help eliminate the sources of the fault.

Do you also develop custom interfaces to third-party devices?

We develop proprietary measurement and control systems and integrate them into our virtual test bench environment. Third-party devices can be integrated there too, and where needed we develop new interface concepts from specifications and datasheets.

Can external devices be integrated into existing systems?

Yes. Whatever the protocol and hardware interface (CAN, Ethernet, USB and so on), we can integrate external third-party devices into existing systems. Measurement data from a customer's own instrument, for example, can be fed straight into our visualisation interface.

Can measurement and test data be visualised to our requirements?

Because the widest variety of measurements is presented in one consistent way, our visualisation of test and analysis data stays clear and easy to follow. The system and its presentation can be tailored entirely to customer requirements.