Cascadia Motion ​offers a host of services for OEMs, Systems Integrators, and end users in a wide range of markets.

Our product development team uses an IATF 16949-compliant product development process applicable to commercial and passenger vehicle applications. We design, prototype, validate, and manufacture low-to-mid volume production programs in our Oregon facilities.

If volumes become large enough to interest a BorgWarner facility then we will be very pleased to “graduate” the project into higher-volume production when the timing and scale is mutually appropriate.

Interested in a custom design? Contact Us Now!

Product Quality

  • The Company utilizes an IATF 16949-compliant New Product Realization Process for development of our catalog and custom products alike.
  • For specialty applications that require it, Cascadia Motion can provide Formula1-levels of production quality assurance. These components and products receive exhaustive pre-and post-assembly inspection, active temperature cycling and burn-in, extensive data analysis, serial / lot number traceability, etc...

Functional Safety

  • ISO 26262 Road Vehicle Functional Safety standard – We have undergone training and certification in this area for our developers and management and with corresponding improvements to our development tools.
  • Safety Culture and FMEAs at all stages of development
  • Functional Safety support for customer program to ASIL-C

Design Verification

  • ISO 16750 - Road vehicle environmental conditions and testing; the standard for electrical and electronic equipment in transportation
  • IEC 61000 EMC standards
  • ISO 6469 High voltage safety standard

Power Circuit

The company has considerable experience with the design of power circuits ranging from a few Watts to 1MW. This includes mechanical layout and complete mechanical design, thermal design, analysis of the losses and temperature rise of the components, laminated bus bar designs, DC link capacitor bank designs, overall system enclosure design and connector systems.

Advanced Thermal Management Design

Extensive thermal design and thermal component and system analysis for air-, water- and oil-cooled circuits, assemblies and systems; Cast, Extruded, Transfer Molded, Injection Molded, and exotic metal matrix materials experience; Custom heat exchanger design and fabrication; Cooling System test and qualification.

Motor Controls

AC Induction and Permanent Magnet motor control algorithms, expertise, and software for industrial, alternative energy, and propulsion system controls.

Motor and Gearing

All aspects of electric motor cooling, lube, packaging including with or without couplings or attached gearing systems.

Power Hybrid and Multi-Chip Module Packaging

All aspects of power module design, including power substrate layout design, die attach tooling and fixture, wire-bonding layout design, gate and power lead frame design, injection molded component design, and comprehensive thermal and electrical analysis.

Drive Module Integration

Combining all aspects of inverter, motor and gearing design gives us unique in-house capability to engineer, prototype and produce your drive module (eAxle) solutions.
State-of-the-Art Engineering Tools
  • 3D Solid Modeling
  • Computational Fluid Dynamics (CFD) simulation
  • Finite Element Analysis (thermal, mechanical FEA) simulation
  • PSIM Power Electronics and Controls simulation (Motor Control, Thermal, and advanced modules)
  • MATLAB / Simulink, Real-Time Embedded Coder, Real-Time Workshop, SimDriveline
  • SPICE electronic circuit simulation (PSPICE and other SPICE variants for power)
  • Mentor Graphics Schematic Capture and PCB layout software
  • Altium Schematic Capture and PCB layout software - with Altium-Solidworks Bridge
  • Document Control, Revision Control, and ECO Process software over VPN
  • LabView automated test system software development environment
  • Power Semiconductor dynamic characterization (Eon, Eoff, Err...) test station
  • 3x Espec Fast Thermal Cycling chambers, also used for Hot/Cold Operation test
  • 1x Espec Cold Chamber -75C
  • 1x Espec Humidity Cycling Chamber
  • Burn-In / Durability Test Station
  • Motor/Generator Dynamometer test stand - 120kW/500Nm/8500RPM, water + oil cooling
  • Motor/Generator Dynamometer test stand - 120kW/3000Nm/3500RPM, water + oil cooling ​
  • 0-800V adjustable DC power source 40kW (loss makeup)
  • Thermal impedance characterization of high power IGBTs, Si and SiC FETs, and Diodes
  • MYDAX chiller -35 .. +105C coolant with up to 10kW continuous heat sourcing or sinking
  • Two 2-post vehicle lifts for in-house EV construction and hybrid conversion
  • Partnerships with ISO/IEC 17025 accredited test labs for additional validation testing
  • Battery cell and module load bank testers
  • Fully-stocked machine shop with 3, 4, and 5 axis machining
Core Competencies
  • Unique know-how and IP in packaging, cooling and interconnecting high power semiconductors, discrete power components, and systems.
  • IGBT and MOSFET modules and custom power hybrids
  • Motor sizing/selection
  • System-level speed/torque/power analysis for gearing selections
  • Bearing and gearing calculations and design choices
  • Advanced composite and metal matrix materials
  • Advanced analysis techniques and methods to accurately predict thermal and electrical results before building a prototype
  • Power circuit electrical and electro-thermal simulation
  • Accurate losses analysis and co-simulation of the power circuit in operation
  • System hardware, system controls, and firmware for DC/DC, DC/AC and AC/DC converter and inverter systems
  • EV / HEV traction and power system design
  • Energy storage system engineering
  • Battery pack design and analysis
  • Battery thermal behavior and electrical models
  • Integrated power electronic control systems
  • Design for manufacturing test systems

Interested in a custom design? Contact Us Now!