Wireless EV Charging Brought to Life
WiTricity partnered with Motivo to develop a robust integration kit for their custom wireless vehicle charging technology
Background
WiTricity, a pioneer in wireless charging technology, had developed a magnetic resonant power transfer system for electric vehicles. While the core technology was proven, it existed as an unrefined proof-of-concept. A partner was needed to transform it into a compact, robust, and manufacturable integration kit that could be installed on popular OEM vehicles, specifically the Ford Mach-E.
Motivo was engaged to engineer a comprehensive solution that addressed every aspect of vehicle integration. The process focused on helping turn WiTricity's innovative technology into a market-ready product.
This transformation required bridging the gap from prototype to production through design-to-cost exercises, time studies, Design for Manufacturability (DFM) considerations, and the ability to identify, vet, and stand up long-term suppliers. Motivo also leveraged in-house capabilities for early batch builds (e.g., 50+ units), including in-house wire harness manufacturing. We then were able to refine the design and assembly process while creating the necessary data packages to help stand up long-term providers.
Blue Mach-E with Witricity System Integrated
The primary challenge was to achieve this integration without direct OEM support. This meant creatively interfacing with the vehicle's complex onboard systems all while ensuring the final product was roadworthy, reliable, and simple enough for a dealership or up fitter to install.
Intelligent System Communication & Control
Without access to OEM protocols, the first task was to enable the vehicle to recognize and accept the wireless charge.
The vehicle's CAN bus communications were meticulously analyzed to understand its charging-related signals and protocols. For firmware development, Motivo leveraged Simulink, a model-based design software development tool, to create and refine the necessary control logic.
Working within existing OEM constraints and interfaces, Motivo leveraged commercial off-the-shelf (COTS) controllers, typically used for stationary charging stations. This approach allowed for the seamless replication of the necessary electronic "handshake," enabling the onboard charge controller to recognize and accept the wireless charge without a physical connection.
Since the stock vehicle display couldn't be used, a dedicated display screen was included to provide the driver with critical positioning feedback and real-time charging status.
Mechanical & Electrical Packaging
Lacking OEM vehicle CAD data, a hands-on, iterative design process was employed using physical templates and cardboard mockups to perfect the placement and design of brackets and enclosures.
Robust, custom brackets were designed that utilized existing mounting points on the vehicle's chassis, ensuring a secure fit without permanent modifications. Most of the critical electronics, including high-voltage charge control, were packaged in a durable, purpose-built enclosure, designed and tested to an ingress protection rating of IP67.
A high-voltage automotive-style harness was also designed for safe and efficient power transmission. The Electrical and Mechanical Engineering teams collaborated closely to design the hardware to safely handle these high voltages, prioritizing user and vehicle safety.
System Assembly
Complete System Prior to Assembly in Vehicle
Environmental Testing
The powerful electromagnetic field generated by the charger posed a risk of heating nearby ferrous components. Custom-formed aluminum shielding was engineered to protect the vehicle frame and critical hardware from EMF exposure, ensuring safety and system integrity.
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Installing Charging Panel
Completed Underside Assembly
Outcome
Motivo successfully transformed WiTricity’s proof-of-concept into a robust, fully documented integration kit. The wireless charging systems were produced and integrated onto a fleet of ten vehicles, including eight Ford Mach-Es and two E-Transits, with each vehicle passing a rigorous acceptance test plan.
E Transit with Witricity System Integrated
The final deliverable was a production-ready solution that met all the client's goals for reliability, manufacturability, and ease of installation. WiTricity was equipped with a polished, professional kit and the comprehensive documentation needed to confidently approach OEM partners and scale their technology.
Capabilities Used
Systems Engineering: Vehicle integration planning; OEM interface strategy; DFMAT; Value engineering.
Mechanical Design & Engineering: Iterative physical design (without CAD); Custom mounting and enclosures; EMF shielding engineering.
Electrical Design & Engineering: CAN bus programming; Electronic handshake replication for charge recognition; High-voltage harness design.
Software Design & Engineering: Dedicated user interface development (for positioning and status).
Prototyping, Fabrication & Assembly: Custom bracket fabrication; Enclosure manufacturing; Fleet integration.
Low Volume Production: Detailed Bills of Materials (BOMs); Comprehensive assembly manuals.
Testing & Validation: Thermal testing (for overheating); Vehicle model compatibility testing; Conventional charger interference testing; Field testing with fleet customers.