Adapting Vehicle Control Logic for New Variants

A pilot project was launched to evaluate a compact electric vehicle’s thermal performance under varying charging and driving scenarios. The project required adapting an existing thermal management controller – originally developed for a different EV model – to support a new battery configuration and control infrastructure. The task: validate feasibility while avoiding the time and cost of developing a new system from scratch.

Synchrotek reused and tailored the core thermal control software to suit the new architecture. This included:

• Reconfiguring control logic to match the new vehicle’s thermal paths and actuator set
• Adjusting calibration parameters for optimal behavior during fast charging and operation
• Running model-based simulations to assess impact and eliminate integration risks early

Supporting vehicle-level testing and refinement in collaboration with the OEM’s pilot team

Despite tight timelines and evolving specs, our modular approach enabled fast adaptation and confidence in system behavior.

Validated concept: The adapted control software successfully
passed pilot validation without major changes.

Cost-efficient reuse: No need to redesign or revalidate the entire software
architecture.

Platform readiness: The pilot vehicle proved the concept and opened the door
for future series deployment using the same control base.