Alma Automotive and Borghi & Saver look forward to welcoming you at Automotive Testing Expo Europe 2025, taking place in Stuttgart from May 20 to 22 at Messe Stuttgart.
This event is the global benchmark for professionals in the field of automotive design, development, and testing. For us, it’s a valuable opportunity to present our EOL and R&D solutions for automotive components.
🤝 Come meet us in person!
Discover the advanced testing and validation solutions developed by Alma Automotive, with a focus on powertrain, engine control, HIL, and DAQ systems, alongside Borghi & Saveri’s excellence in the production of active and passive dynamometric test benches.
Together, we offer a synergistic and complete approach to automotive testing, ready to meet the challenges of electric, hybrid, and connected mobility.
Event details:
📍 Booth 1250, Hall 10
📅 May 20–22, 2025
🌍 Messe Stuttgart, Germany
We’ll be glad to welcome you at our stand and share ideas, visions, and technologies that shape the future of the automotive industry.
Don’t miss it!
Saleri, a leader in the design, development, and production of Thermal Management systems and cooling solutions for the automotive sector, reaffirms its commitment to delivering increasingly high-performance and reliable products. To achieve this goal, the company has chosen to leverage high-voltage testing technology from Alma Automotive, a spin-off of the University of Bologna with over 20 years of experience in developing testing solutions.
With the installation of three dedicated testing chambers, each equipped with data acquisition systems and high-power-density power supplies, Saleri will be able to conduct in-depth and entirely safe testing of both its standard devices and next-generation solutions designed for electric mobility.
The system has been customized to meet the needs of Saleri’s technical experts, allowing them to carry out testing and development activities independently in a controlled and risk-free environment.
Alma Automotive developed the project from scratch, aiming to meet the required technical specifications while staying within the agreed budget.
The 15-meter-long cabin has been divided into three independent areas, each designed to address specific operational needs. Every space features a dedicated electrical system and an air exchange system, essential for ensuring optimal conditions during testing. Additionally, the wall panels have been soundproofed with high-performance materials, reducing noise by at least 30 dB.
To ensure maximum precision and reliability in testing processes, each chamber is equipped with a custom-designed data acquisition system based on National Instruments hardware. This system enables highly accurate monitoring of all relevant parameters, ensuring a thorough performance analysis of the device under test.
The new test facilities allow devices to be powered up to 1000V, an operation that must be carried out with maximum protection for operators.
To minimize risks, several safety measures have been implemented, including insulation testers and a four-phase light signaling system that instantly indicates the operational status of the test cell at a glance.
Additionally, door sensors have been installed to automatically interrupt the test and discharge the HV and LV buses in the event of unauthorized access, providing an extra layer of protection even during ongoing operations.
The collaboration between Saleri and Alma Automotive brings together two leading players in their respective fields, creating a synergy that will drive increasingly advanced solutions in development and testing. Through this partnership, Saleri further strengthens its innovation capabilities by leveraging Alma Automotive’s expertise and technology to optimize its testing and validation processes.
For more information about Alma Automotive and its testing solutions: info@alma-automotive.it
We are proud to continue supporting Ducati in its development and testing activities, strengthening a partnership that has lasted for over twenty years!
Our passion for engineering meets the excellence of the Motor Valley to push the boundaries of innovation even further.
Saleri is leader in the design, development, and production of Thermal Management systems and cooling solutions for the automotive sector, recognizes the crucial importance of thorough testing to ensure optimal performance and safety of its components for next-generation electric vehicles.
Through its collaboration with Alma Automotive, expert in advanced technological testing and development solutions, the Saleri Group will leverage state-of-the-art testing facilities and equipment to conduct detailed thermal analyses and validate its products tailored for the electric mobility market.
The partnership with Alma Automotive marks a significant step in our mission to deliver cutting-edge solutions in the field of Thermal Management for electric vehicles.
Matteo Doi, Testing & Simulation Director, Saleri Group
Their expertise and innovative testing infrastructure will enable us to provide our clients with the highest levels of quality and reliability.
"Alma Automotive is thrilled to collaborate with the Saleri Group to drive innovation in the electric mobility sector. Our state-of-the-art testing technology will allow the Saleri Group to conduct in-depth tests and accelerate the development of advanced solutions" comments Enrico Mosconi, Business Development Manager, Alma Automotive
The partnership between Alma Automotive and the Saleri Group represents an excellent synergy between two industry leaders, promising to deliver new and innovative solutions for the electric mobility sector.
Predictive maintenance in the industrial machinery sector is a crucial strategy for ensuring plant reliability and efficiency. Its primary goals include reducing operational disruptions and costs associated with unexpected failures. By constantly monitoring the condition of machines through sensors and advanced technologies, any signs of malfunction or wear and tear can be identified early, enabling targeted and planned interventions to prevent serious and costly failures. This helps extend the useful life of machines and optimize the use of human and material resources.
The WARNN system, developed by Alma Automotive, allows key values of machine operation to be monitored.
Using Artificial Intelligence, WARNN builds a digital twin of the observed machine and compares all acquired data with the corresponding reference values in case of optimal operation.
Thanks to this process, it is possible to anticipate faults and understand when the machine is deviating from its standard operation, triggering a whole series of alarms that enable its maintenance.
Predictive maintenance greatly improves workplace safety, as it reduces the risk of sudden failures and accidents. This approach promotes continuous, high-quality production, ensuring maximum operational efficiency. The implementation of advanced technologies such as IoT and data analytics enables the collection of detailed information on machine performance, identifying significant trends and providing valuable information for future decisions.
The advantages for companies are significant, as predictive maintenance promotes sustainable production with lower environmental impacts and optimized maintenance costs. This approach improves company reputation, attracts new customers, and stimulates industry growth through a constant search for technological innovation to optimize industrial plant management.
Alma Automotive has been in support of Ducati Motor Holding for over twenty years, developing calibration and control strategies and conducting test activities for motorsport engines.
Ducati Motor Holding has found in Alma Automotive a solid technical partner to embrace the new challenges of global mobility. Over the past years Alma Automotive has gained extensive expertise in electrification, thanks to significant investment in research and development with a particular focus on dedicated testing solutions for electric vehicles.
With the ability to internally develop control and test equipment, power electronics and hardware-in-the-loop (HIL) systems, the group can support manufacturers in the full development and testing of hybrid, electric, and traditional powertrains. The availability of internal test cells and collaboration with qualified engineers allow Alma Automotive to be a comprehensive partner in supporting the most innovative powertrain development activities.
The transition to electric powertrains brings about new challenges in predicting when something might go wrong and in keeping the powertrain healthy. While traditional diagnosis methods have their merits, they often provide only a limited opportunity to address the dynamic evolution of potential dangerous conditions in electric powertrains, where the interplay of numerous intricate electronic components and complex systems requires a more sophisticated approach to monitoring and diagnostics.
ESACO (Electric powertrain System Anomaly detector and Conditions Observer) has been developed in response to the urgent need for improving the safety, reliability, and performance of electric powertrains. As electric vehicles (EVs) become increasingly prevalent in the automotive landscape, ensuring their safety and reliability is paramount.
ESACO's scope extends beyond just enhancing individual electric powertrains; its goal is to optimize their usage and integration into the transportation landscape. Utilizing advanced diagnostic and predictive technologies, ESACO aims to enhance the reliability and performance of electric vehicles, thus facilitating their wider adoption. This contributes to mitigating environmental impact by reducing emissions and advancing sustainable transportation solutions.
The availability of comprehensive electric vehicle powertrain data, along with the capacity to effectively manage it, enables the utilization of AI-based trained algorithms. This integration represents a powerful and innovative approach for real-time monitoring of powertrain health, allowing for the early detection of anomalies and potential issues.
By leveraging advanced artificial intelligence techniques, such as machine learning and predictive analytics, these algorithms can analyze vast amounts of data to identify patterns and trends indicative of developing problems. This proactive approach not only enhances the reliability and performance of electric vehicles but also contributes to minimizing downtime and maintenance costs, thereby optimizing the overall efficiency and usability of electric powertrains in various mobility applications.
The CNMS Program (CN00000023) funded by the European Union – Next Generation EU, under the PNRR MUR – M4C2 Investimento 1.4. " Potenziamento strutture di ricerca e creazione di “campioni nazionali di R&S" allows Alma Automotive to leverage the skills and knowledge acquired in battery testing and mathematical modeling to develop an advanced technological solution for real-time monitoring of battery pack health.
The goal of ARISBE is to develop a system based on Edge-Cloud architecture, with the primary objective of increasing the safety and efficiency of electric propulsion systems through the monitoring of battery packs installed in vehicles.
The system consists of two main components: the Edge device and the Cloud application. The Edge device is connected to the vehicle’s Battery Management System via CAN bus and collects measurements to assess the battery's health status. The raw data is processed using AI algorithms to extract numerical indices and determine if the battery is operating under nominal conditions. The results are sent to the cloud, where data on the battery pack's health is stored and made available to users through a smart web interface. The cloud domain enables more complex analysis of historical data, device comparisons, and the implementation of alarm systems. Data availability can be selectively restricted, allowing access for different categories of users, including battery manufacturers, maintenance personnel, end-users, etc.
This project born from the desire to use smart and innovative technologies to drive the decarbonization process, in line with the objectives set by the European Community.
The project will result in a validated prototype of the system installed on a vehicle. The Research & Development project includes total investments of €292,254.00, funded by a contribution of €184,144.00.
The CNMS Program (CN00000023) funded by the European Union – Next Generation EU, under the PNRR MUR – M4C2 Investimento 1.4. " Potenziamento strutture di ricerca e creazione di “campioni nazionali di R&S” allows Alma Automotive to leverage the skills and knowledge acquired in the design of DC-DC motorsport systems to develop a new high-efficiency DC-DC converter for hydrogen-powered and battery-electric vehicles.
The goal of the HyMC Project is to develop a modular DC-DC converter prototype for automotive applications based on hydrogen fuel cells.
Hydrogen-powered electric propulsion represents an alternative to systems that rely solely on batteries. One of the key components for the development of such a propulsion system is the DC-DC converter, which interfaces the output of the fuel cell to the high-voltage bus of the vehicle’s powertrain, enabling optimal management of energy flows. The base unit of HyMC is a 15kW DC-DC converter that can be paralleled. The system’s modularity allows it to be adapted to various propulsion system sizes, up to 90kW. The proposed device will incorporate innovative techniques to achieve high efficiency in a compact form factor, such as Partial Power Conversion, resonant LLC conversion topology, and the use of Wide Bandgap semiconductors. The detailed design requirements will be defined in close collaboration with the proposing entity, sharing the decisions made for the system’s implementation. The design criteria will consider the specific needs of automotive applications, aiming to optimize efficiency without sacrificing size, weight, and vehicle integration.
The output of the project will be a functional prototype validated in the laboratory.
The Research & Development project includes total investments of € 215,541.00, funded by a contribution of € 133,265.00.
Introducing the DC-DC 800V-48V electronic converter, our powerhouse solution specifically developed for motorsport with voltage conversion up to 550W.
This cutting-edge device features two specialized boards: the High-Voltage Board orchestrates an isolated conversion from 800VDC to 48VDC using advanced LLC resonant converter technology, while the Low-Voltage Board leverages GaN Mosfets Technology to efficiently transform 48VDC to 14VDC, all packed into a sleek, compact design.
Experience power and efficiency like never before.
Our DC-DC 800V-48V is built with two different boards:
Alma Automotive power converter has been designed to be vibration resistant, with particular focus for severe ambient use.
The DC-DC is equipped with on-board data acquisition such as: load current, bus voltages, environmental temperature, pressure and VOC, actuator status and other. It is also able to drive and communicate with the actuator for the charge port using the CCS2 protocol. This DC-DC also has a 48V PWM out to supply a pump driver up to 400W and a 12VPWM. The DC-DC has an integrated BOOST module, so it is possible to power-on and supply load on 12V Chassis up to 80W with an external Kicker Cell. The LV board provides an on-board charger to recharge the Kicker Cell when the DCDC is powered by High-Voltage or external power supply (Jump Battery).
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