How PEM Motion Supported EASEE's Safety and Reliability in Charging Solutions
Dealing with product safety challenges can be daunting, especially when legal disputes and regulatory scrutiny come into play. However, with the right expertise and collaborative approach, companies can overcome these obstacles and emerge stronger. PEM Motion exemplified this by becoming the trusted partner of EASEE, a Norwegian developer and manufacturer of EV charging solutions, ensuring their products met the highest safety standards and maintained customer reliability.
Addressing Initial Safety Concerns
In late 2022, EASEE faced compliance discussions in Germany concerning their Home & Charge product. The situation arose from challenges related to product safety standards centered around an RCD component.
To address these concerns, EASEE collaborated with PEM Motion. Supported by Gerd Macherey, Director of the Engineering & Validation Business Unit, PEM Motion’s experts Jochen Theil and Marvin Müller evaluated existing documents and prepared technical reports. Their work focused on demonstrating the safety and compliance of the product with relevant standards. These reports were crucial in resolving the issues and ensuring that EASEE met EU directives effectively, thereby opening the door to a long-term collaboration.
Overcoming Regulatory Challenges and a Swedish Sales Ban
In spring 2023, EASEE faced another hurdle—a sales ban from Swedish authorities, leading to a court case upon EASEE’s appeal. Other European countries followed the Swedish authority’s assessment. The ban stemmed, among other reasons, from incomplete technical documentation for the Easee Home and Charge products.
Driven by circumstances and discussions with authorities, EASEE decided to launch a new version of the Charger, accompanied by new technical documentation and adhering strictly to current standards. PEM Motion’s new employee, Andreas Bauten, joined the team of Marvin and Jochen, playing a vital role in developing comprehensive technical documentation for this new Charge Lite aimed at a quick market launch. Together with EASEE’s team, they integrated updated technical documentation, with the primary objective of demonstrating safety and compliance of the product, through meticulous steps.
In the first step, a new requirements management system was implemented. All applicable EU directives and regulations that must be fulfilled were restructured and linked to the product’s functionalities, demonstrating their relevance. Harmonized standards were supplemented and referenced to ensure compliance with the fundamental requirements of these directives and regulations.
Next, in the second step, the risk assessment underwent revision using a PEM Motion developed template tailored for generic risk assessments according to ISO 12100. While this standard originates from the machinery sector and is listed under the Machinery Directive, its applicability extends to electrical and radio equipment, reflecting contemporary practices in risk assessment. In addition to adhering to standards, supplementary mitigation measures were identified.
The final step focused on verifying compliance with all requirements. A validation plan was meticulously crafted for this purpose, consolidating all requirements and documenting their compliance. PEM Motion’s predefined template was employed to outline this plan, encompassing previously specified requirements and corresponding mitigation strategies. The resulting test items—including document checks, physical inspections, and visual assessments—were meticulously documented, specified, and linked to corresponding test reports.
These documents were complemented with detailed explanations and appended to the technical documentation. A master document outlined the entire structure of the technical documentation.
Marvin Müller, Project Lead at PEM Motion, commented, “We have enjoyed working with EASEE from the very first minute. We encountered innovative products and competent people. However, at certain points, there was a need for more structure and detail, and we are glad to have supported EASEE in making the necessary improvements. We were amazed by their eagerness to expand their knowledge and willingness to enhance their documents and processes.”
EASEE opted for a voluntary EU-type examination and submitted these documents to TÜV Rheinland, which serves, among other roles, as the notified body for the German Federal Network Agency (Bundesnetzagentur) under the Radio Equipment Directive. This successful process strengthened EASEE’s confidence and provided customers with renewed safety assurance.
“Working with PEM Motion was transformative. Their proactive approach and comprehensive support helped us overcome significant challenges and ensured our products met the highest safety standards. We greatly appreciate their partnership,” said Lasse Kalheim, EASEE’s Product Manager Chargers.
Enhancing Product Functionality and Safety
This spring, EASEE introduced the new Charge Core, as an option to the Charge Lite for larger installations. Similar to the Home & Charge, the innovative implementation of the RCD function also involved deviations from current standards. Therefore, EASEE decided from the outset to collaborate with PEM Motion to obtain an EU-type examination from TÜV Rheinland. The resulting functional safety assessment was supported by PEM Motion’s experts Melek Eker and Lisa Weichsel, with additional resources from PEM Motion.
The assessment was led by Lisa Weichsel, a certified functional safety engineer, and supported by staff from PEM Motion and EASEE. The goal of this assessment was to demonstrate that the innovative RCD function solution achieves at least the same safety standards as the current state of the art.
The assessment was based on the internationally recognized standard IEC 61508 for functional safety. Initially, the risk assessment of the Charge Lite was adapted to the Charge Core, and the safety function was identified. The technical implementation of this function underwent detailed analysis. This involved identifying all safety paths with relevant components and software analysis. Additionally, the reliability of components was assessed using Failure Mode and Effect Analysis (FMEA) to determine whether the required Safety Integrity Level (SIL), as per IEC 61508, was achieved.
Theoretical assessments were complemented by various internal and external tests conducted on the actual product at independent laboratories. The entire assessment process was conducted in close collaboration with TÜV Rheinland.
Ongoing Support and Future Plans
PEM Motion continues to stand by EASEE as they prepare to launch more chargers, ensuring that each product meets or exceeds rigorous safety standards. This involves thorough analysis and adherence to regulatory requirements.
Christoph Deutskens, CEO of PEM Motion, emphasized, ‘PEM Motion’s expertise and dedication were essential in navigating the complex regulatory landscape, fostering direct communication and unwavering support that were pivotal in restoring EASEE’s client confidence and trust.’
In addition to the specific work on the various chargers, EASEE aims to modernize fundamental structures and processes in requirements management and technical documentation. PEM Motion is involved in this project and supports EASEE in these endeavors.
Customer Satisfaction and Trust
EASEE highly valued PEM Motion for its expertise and transparent communication, which fostered a strong and trustworthy relationship. PEM Motion’s steadfast support was instrumental in helping EASEE regain confidence during challenging times. EASEE demonstrated unwavering commitment to its products, company, and especially its customers, showcasing unbelievable resilience and tenacity. While EASEE’s product innovation remained unquestioned, PEM Motion effectively managed technical documentation challenges.
The collaboration between PEM Motion and EASEE underscores the importance of expertise, clear communication, and unwavering support in overcoming product safety challenges. Together, they ensured EASEE’s products not only met regulatory standards but also successfully worked on restoring customer trust, paving the way for future success.