Inside Our Testing: BMS Failures, Fixes, and Lessons Learned

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Published 2024-07-28
We're going to show you something different that no other OEMs do. We’ll take you through some of the challenges we’ve faced and the things we’ve broken on our Diesel Electric Hybrid over the past two to three months of testing.

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00:00 - 00:24 Introduction and Overview
00:24 - 01:25 Inducing Low Voltage Failure
01:25 - 02:04 Working on Topsy
02:04 - 02:51 Replacing BMS and Cooling Issues
02:51 - 03:18 BMS and Battery Management System
03:18 - 03:55 Replacing Inductor Coil and Voltage Update
03:55 - 05:01 Battery Testing and Safety Procedures
05:01 - 10:25 Programming and Generator Testing
10:25 - 12:33 Truck Testing and Overheating Issue
12:33 - 18:17 Hybrid System Testing and Lessons Learned
18:17 - 20:13 Regenerative Braking and Voltage Spike
20:13 - Outro and Future Plans

All Comments (21)
  • This just shows how much you care about your product, not just “it’ll be fine, if it breaks they can fix it” it’s the push to make sure if things fail you can still keep going until you get to where you need to be
  • I love that Edison is doing it themselves. They are not outsourcing it to a third party that is trying to adapt someone else’s code. This means you have intimate knowledge of how everything works. These first few trucks are the next step in testing, Topsy is that crucial prototype to set your base line. Keep working and testing and finding the edge cases that break things.
  • @capnkirk5528
    That multi-screen coolant temperature is the kind of thing that really adds to repairability. Often, the biggest challenge is diagnosing a problem, which will also help the driver decide if it's STOP NOW or FIND A PLACE. Love the info and transparency, hope you guys are prepared to scale when the time comes!
  • @johngato737
    I work on the field service side of the industry for an OEM you’re familiar with. I cannot get enough of what you’re doing. Much support keep it up. I support hydrid
  • @ianmckay1780
    This is why testing is so important. The more you test, the more you understand what went wrong, and why, and even more important, how to fix it so it doesn't reoccur. Then with all that data, you have to go through it line by line to see what came first. Then you can work through the system, problem solving as you go. Absolutely brilliant piece of micro management as it should be performed. You have the perfect team put together, who can work together, and solve potential problems, before they become actual problems. I love the work you are doing, to produce your first truck for sale. It will have been built by people who know what, where, and why, and can advise as necessary. Superb engineering in the flesh. This is how it should be done, and with the right team behind you, and all things being equal, you have the ethos to build safe, efficient and technologically advanced products to be proud of. GOOD LUCK in the journey and even better, best wishes for all of you.
  • @capnkirk5528
    Kudos to the senior management team at EMCON for having the foresight to get on board! Seriously, I have seen their trucks in Ontario and seeing a company like EMCON actually getting on board and looking forward makes you feel better about where the MoT is spending their money. Would love to see Edison Trucks with an EMCON logo clearing the 401!
  • @ARockRaider
    at the rate you guys are going, this will be the hardest truck to actually break down out there! as long as nothing in the drive axles lock up.
  • @akabruno1
    I really appreciate all the love of design you guys have for this project. I've been saving for years that we needed a diesel gen set on an electric truck. A#1
  • @LukeTowers
    Love the detailed insight into the process, keep up the amazing work!
  • @janjaap102
    I ame soo happy to see some actual product development is going on. Without all the bs of sales cut out, soo you see the real picture.
  • I am SO HAPPY to see you guys learning from your mistakes. I love how you demonstrate trial and error. I've started trying to implement that in my life as I begin my IBEW electricians apprenticeship!
  • What a refreshing approach to designing, building and supplying a top notch product. 100% support the work you guys doing. My only thought was to install a capacitor to help handle the voltage fluctuations when regeneration occurs. Keep up the incredible work boys!
  • @kaceesavage
    So glad for the update! Keep on truckin’ boys!
  • Thanks for a great update and showing everyone what real R&D is made from. Lots of thinking, testing, and redesign. Glad you are not putting the product on the market prematurely and having unhappy customers finding all the problems like some other companies do.
  • As a product development engineer in BC, in the work truck space this is SO cool to see GOOD engineering and thought. Keep doing the good work boys 💪
  • @danielmadden7141
    Really appreciate you allowing us to take this adventure with your group and have a hands on stilled experience!
  • @bbeen40
    Can you imagine how good your Ford or Chevy would be if those companies cared this much? Keep up the good work brothers!
  • IU am so impressed by your whole enterprise. Intelligent design, thoughtful redundancy, and wholesome/humble attitude makes me wish I was 35 years younger and could work for/with you guys. Keep it up :)
  • It’s beautiful it seems like an entire community is putting this truck together.
  • @jaustinpage
    We need more of this on YouTube. Thanks guys!