The HyMC project has been carried out within the CNMS Programme (CN00000023), funded by the European Union – NextGenerationEU through the PNRR MUR funds – M4C2, Investment 1.4: “Strengthening research infrastructures and creating national champions of R&D on selected Key Enabling Technologies”.
Thanks to this programme, Alma Automotive is applying its expertise in the design of DC-DC converters for motorsport to develop a new generation of high-efficiency DC-DC converters for hydrogen- and battery-powered vehicles.
The main goal of HyMC is the development of a modular DC-DC converter prototype for electric vehicles with hydrogen fuel cells.
Hydrogen represents a promising alternative to technologies based solely on batteries. In this context, the DC-DC converter is a key component: it enables the connection between the fuel cell output and the high-voltage bus of the powertrain, optimizing the vehicle’s energy flows.
Alma Automotive successfully developed a working prototype of a modular 15 kW automotive DC-DC converter, based on the Partial Power Conversion topology.
The system is designed to interface with fuel cells operating from 150V to 250V and to supply battery powertrains up to 800V.
Thanks to the selected topology and the use of innovative components, an average efficiency higher than 96% was achieved.
The converter control system, fully developed in-house for this application, allows complete monitoring of all operating parameters, ensuring stable output in current, voltage, and power. This enables optimized energy management aimed at preserving the state of health of fuel cells and batteries, while reducing current transients and inefficient operating zones.
The prototype was designed to be scalable and adaptable to different operating configurations, in terms of power, input voltage, and output current.
The project involved a total investment of €215,541.00, supported by public funding of €133,265.00.
ARISBE (Artificial Intelligence System for BEV Enhancement) is a project developed within the CNMS Program (CN00000023), funded by the European Union through the PNRR MUR – M4C2, Investment 1.4 "Enhancement of research infrastructures and creation of national R&D champions on Key Enabling Technologies."
Thanks to this funding, Alma Automotive is leveraging its expertise in battery testing and mathematical modeling to develop an advanced technology solution for real-time monitoring of battery pack health.
The goal is to create an innovative Edge-Cloud-based system to improve the safety and efficiency of electric powertrains by monitoring the batteries installed on vehicles.
The system consists of two main elements:
Data access can be configured for different user types: battery manufacturers, maintenance technicians, end users, etc.
ARISBE aligns with the European Union’s decarbonization strategy, using smart and innovative technologies to support the green transition.
The project successfully led to the development of a fully functioning prototype, tested on an electric vehicle, capable of real-time monitoring of the battery pack’s State of Health (SoH) using data from the BMS.
The advanced AI algorithms embedded in the edge device ensure both accurate health estimation and continuous anomaly detection.
The prototype’s usability was ensured by implementing an Edge-Cloud communication architecture, allowing real-time and online monitoring of all key battery indicators during vehicle operation.
The project involved a total investment of €292,254.00, of which €184,144.00 was funded through the European contribution.
Get in touch for more information or to explore new collaboration opportunities!
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
For 2025, Alma Automotive confirms its role as Official Supplier to Ducati Motor Holding.
This recognition reinforces a technical partnership that has evolved over more than twenty years, built on shared goals, continuous innovation, and mutual trust.
Alma Automotive works alongside Ducati to develop advanced calibration and control strategies, supporting the testing of high-performance racing engines, both combustion and electric.
The collaboration brings together the engineering heritage of Italy’s Motor Valley with our flexibility and deep expertise in engine calibration, test bench management, and the development of advanced control strategies for traditional, hybrid, and electric powertrains. With in-house test cells and a dedicated team of engineers, Alma Automotive provides end-to-end support in key areas such as:
A partnership that reflects Alma Automotive’s mission: enabling the mobility of tomorrow through technology, precision, and uncompromised performance
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.
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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