Current openings at Lightning-Hybrids, Northern Colarado

Lightning Hybrids is an automotive research and manufacturing company based in Loveland, Colorado. They develop and produce the Energy Recovery Systems (ERS), hydraulic hybrid upfit for urban medium- and heavy-duty vehicles like delivery trucks and buses, which save fuel and reduce harmful emissions.


Current Openings

1.Data Analyst

Responsibilities Include:

  • Interpret and analyze big data (from both test and field) using statistical methods to provide key insights to hybrid system performance
  • Aid in developing and managing databases, analytics systems, and reporting tools
  • Use data to make business and engineering recommendations based off of results
  • Use data to create predictive analytics to make future business and engineering recommendations
  • Work with Customer Operations and Engineering teams to process data quickly and efficiently
  • Build tools to allow others within the organization to easily access information and data sets


BS in Computer Science, Mechanical Engineering, Mathematics, or Statistics is preferred.


2+ years of data mining or data analyst experience. Experience with vehicle or hybrid systems is preferred.

Send resume and cover letter to with “Data Analyst” in the subject line.

2.Engineering Tech – Mechanical

Position Summary:

Mechanical Technician working closely with design engineers on R&D projects relating to hydraulic hybrid systems.  Position includes:

  • Manufacturing skills: machining, welding, forming, finishing, assembly
  • Mechanic skills: driveline, engine, transmission, differentials, fluids
  • Support engineering design and drawing reviews
  • Buyer for engineering R&D related components/equipment
  • Take engineering designs from procurement to test completion
  • Testing setup and support
  • Ability to follow verbal and written direction
  • Self-starter, able to work without direction when required
  • Able to multitask and easily shift direction
  • Ability to think outside the box, continual improvement

Salary Range:

$40k – $60k, Salary is commensurate with education and experience.


GED equivalent required, advanced education preferred.


Advanced Level Position.  5+ years manufacturing experience/automotive/hydraulic experience preferred.

Send resume and cover letter to with “Engineering Tech – Mechanical” in the subject line.

3.Assembly Lead/Production Manager

Position Summary:

Participate in and drive the growth and evolution of the Company’s Production Procedures and Processes as we transition from a development based company to a product based company focused on satisfying the Customer’s needs for a “Quality Product” delivered “On-Time.” Position Includes:

  • Manage 4 – 10 direct-labor employees to meet Product Quality and On-Time Delivery Metrics
  • Maintain a material balance between Assembly Line Consumption and Inventory/Procurement Supply
  • Maintain compliance with all Company safety policies
  • Maintain compliance with all Company Quality Procedures and Processes
  • Maintain compliance with all Company Production Procedures and Processes
  • Maintain excellent flow of information throughout the company
  • Other duties which may be required to meet Company goals and objectives


  • Bachelor’s Degree in Business Administration or Operations Management or equivalent experience


  • Minimum 5 Years supervisory experience
  • Experience in working with flow manufacturing, safety procedures and policies, ERP Systems, ISO 9001

Send resume and cover letter to with “Assembly Lead/Production Manager” in the subject line.

4.Assembly Technician

Position Summary:

  • Assembly of high pressure hydraulic regenerative braking system in compliance with all applicable company procedures and processes
  • Assembly of proprietary PTM units in compliance with all applicable company procedures and processes
  • Maintain a clean and organized work area
  • Assist with operation of the dyno test stand when needed
  • Assist with other shop duties as necessary

Education and Experience:

  • 3-5 years manufacturing experience

Salary Range:

  • $15-$18 per hour depending on experience

Send resume and cover letter to with “Assembly Technician” in the subject line.

Job Location:

HYLIION develops add-on hybrid system for semi trailers; Innovation here is the way of applying hybrid tech to trailers

Hyliion has developed an add-on hybrid system for tractor-trailers that will reduce fuel consumption by about 30% with a return on investment of less than one year, according to Thomas Healy, CEO and founder of the Pittsburgh, PA-based startup.

Hyliion’s add-on hybrid electric drive system for tractor trailers

“What makes our system unique is that we solely focus on the trailer,” Healy said to Off-Highway Engineering. “We replace the existing rear axle assembly under the trailer with an electric propulsion system. So now what happens is when the vehicle is slowing down or going downhill, we’re able to capture all that wasted energy and store it in the battery pack on the trailer.”

When the truck accelerates or starts an uphill stretch, the system drives the rear tires on the trailer. “So the diesel engine in the truck doesn’t have to work as hard, there’s not as much load it needs to pull,” he said.

The intelligent electric drive axle system was recently awarded the grand prize in the 2016 “Create the Future” Design Contest produced by Tech Briefs Media Group, beating out more than 1100 product ideas from 71 countries. The contest was co-sponsored by COMSOL and Mouser Electronics, with Analog Devices and Intel serving as supporting sponsors.

Most conventional hybrid strategies integrate an electric motor into the drivetrain of the truck. “Since we don’t integrate right into the drivetrain, you can keep all that existing equipment and not make any modifications to it. We’re getting the benefits of a hybrid system but with an add-on solution,” Healy said.

Essentially, Hyliion is turning a passive axle into a drive axle. “It’s like taking one of the axles off the truck and putting it on the trailer,” he explained. “So now we have a drive axle that we can apply positive and negative torque, with an electric motor connected to the axle.” The electric motor is connected to a control system with a lithium-based battery pack.


The company leverages existing components to help bring the product to market faster. For example, the axle is a production component that’s already been tested and has the weight rating certifications needed to travel over the road.

The system can be installed on nearly every trailer type in less than one hour, the company claims, without changing trailer height or length.

The electric drive axle system is categorized as an auxiliary power unit (APU), capable of powering auxiliaries overnight such as electronics and air-conditioning. Even though the system adds about 500 lb (227 kg) to a tractor-trailer, “the government in most states allows you to carry anywhere from 400-450 extra pounds of payload if you’re running an APU. So it’s really not netting much of a loss of cargo that you can carry,” Healy said.

The electric drive axle doesn’t have any data communication with the truck. The system’s sensors are able to determine when to apply power and when to capture energy. It does have cellular communication and satellite, so the vehicle can be tracked.

“From a fleet standpoint, you can look at how fast your trailers are moving and where they’re located, and we can do things like tell you how much load is in the trailer,” Healy said.

Information is available to the driver via a mobile dashboard application. The driver has the ability to turn the system on and off.

“Our single product is able to propel you above those mandated requirements,” said Healy. “We see it being a perfect solution for this new Phase 2 mandate that’s coming out. From a timing standpoint, it couldn’t be better.”

Hyliion currently has six trucks running with its system for internal testing and validation. “The next phase is we’ve got over 30 fleets that have signed into our pilot program that we’re going to start delivering units to before the end of this year,” he said.

In-house production of the electric drive axle system is expected to begin Q1 2017, and the company is lining up outsourced production for higher volumes in Q2 2017.

“Our next big milestone is really setting up the production,” Healy shared. “There is a lot of demand in the industry for a product like this…How can we manage all the production and supply chain so that we can grow at a very fast pace and get our partners alongside us to grow at the same rate? Our mindset is scaling up production as fast as possible to as high a volume as possible.”

Via: SAE

Hyundai to offer IONIQ EV as subscription vehicle through WaiveCar ; Thanks to advertising dollars for first 2 hours free usage

Hyundai IONIQ as a subscription vehicle by WaiveCar. Image Credits:

LOS ANGELES /PRNewswire/ — Hyundai Motor and WaiveCar, the world’s first all-electric car-sharing program that runs on advertising dollars, today announced a partnership that will expose millions of shoppers to the all-new Hyundai IONIQ electric compact car for free.

The partnership, proposed by WaiveCar as part of Hyundai’s Project IONIQ open call, gives consumers the ability to drive IONIQ EVs on-demand for two hours at no charge. In exchange, the vehicle is wrapped in advertising and includes a roof mounted digital display, which generates the advertising revenue WaiveCar uses to offset costs. WaiveCar’s digital displays are 4G connected enabling dynamic, geo-targeted advertising tailored to ones driving location and time of day. For example, while sitting in morning traffic on the 405 freeway, the ad could read, “This commute would be a lot more comfortable in a Hyundai IONIQ.”


“WaiveCar presents some great solutions for us,” said Mark Dipko, director of corporate planning and strategy at Hyundai Motor America. “The IONIQ offers emissions-free transportation to on-the-go Angelenos. This partnership allows us to reach potential customers and give them the opportunity to test drive our outstanding IONIQ electric while generating awareness for the IONIQ brand at the same time.”

The program, which will launch in early 2017, is Hyundai’s first large-scale involvement in car-sharing and is aimed at making it easy for those without a vehicle to access short-term, free, and engaging transportation. Customers can simply download WaiveCar’s app for iPhone or Android, find an IONIQ near them, book it and start driving — no cards or keys necessary. WaiveCar then unlocks the door for consumers remotely, where they can find the keys inside. Insurance is also part of the all-inclusive-deal.

Users can drive an IONIQ for free for 2 hours at a time. They can continue to drive for just $5.99 an hour or return the car at any designated spot for the next user to pick up. This free floating car-sharing model allows more users to use the same car, which reduces congestion and pollution on a much larger scale.

WaiveCar plans to add 150 IONIQs which will be deployed throughout Los Angeles in the first half of 2017. WaiveCar is planning to launch in three additional cities by the end of 2017 using 250 more IONIQs.

“We are extremely excited to be working together with Hyundai,” said Zoli Honig, WaiveCar’s CTO & Co-Founder. “Providing low cost, eco-friendly transportation alternatives to consumers is our core mission and offering the IONIQ will accelerate that goal. We believe this partnership will be tremendously beneficial for Hyundai, WaiveCar, our customers, and the environment.”

Hyundai IONIQ
The IONIQ line of cars are designed and optimized to give customers an easy transition to environmentally-responsible mobility. The IONIQ is available in three distinct electrified powertrains: the IONIQ electric, IONIQ plug-in and IONIQ hybrid. Regardless of powertrain choice, the platform accommodates five-passengers comfortably and provides the largest cargo capacity in its class. The IONIQ electric models that will go into the WaiveCar fleet provide an EPA-estimated 124 miles of range, and offer Apple CarPlay®, Android Auto® and wireless charging for smartphones.

Hyundai Motor America, headquartered in Fountain Valley, Calif., is a subsidiary of Hyundai Motor Co. of Korea. Hyundai vehicles are distributed throughout the United States by Hyundai Motor America and are sold and serviced through more than 830 dealerships nationwide. All Hyundai vehicles sold in the U.S. are covered by the Hyundai Assurance program, which includes the 5-year/60,000-mile fully transferable new vehicle limited warranty, Hyundai’s 10-year/100,000-mile powertrain limited warranty and five years of complimentary Roadside Assistance. Hyundai Blue Link Connected Care provides owners of Hyundai models equipped with the Blue Link telematics system with proactive safety and car care services complimentary for one year with enrollment. These services include Automatic Collision Notification, Enhanced Roadside Assistance, Vehicle Diagnostic Alert, Monthly Vehicle Health Report and In-Vehicle Service Scheduling.

Via: prnewswire


Workhorse Group Signs Agreement With BMW i For Range Extender

BMW i3 REx integrated into Workhorse Range-Extended Step Van

CINCINNATI,Workhorse Group (NASDAQ:WKHS) announced that BMW i has signed a multi-year supply agreement for BMW i3 range extender (REx) units for the Workhorse E-Gen electric delivery vehicle.  The Workhorse E-Gen delivery vehicles are used by last mile delivery companies to fulfill their customers’ delivery needs.

BMW’s proven Range Extended solution is powered by a 647 cc two-cylinder gasoline engine that engages when the battery level drops to a pre-determined state-of-charge, acting purely as a generator to produce electricity to extend the range of the Workhorse E-Gen vehicle.

“The REx solution adds tremendous benefits to our E-Gen vehicle and to our customers.  Signing this supply agreement with BMW further strengthens our commitment to our customers’ fuel efficiencies, maintenance savings, and sustainability initiatives while continuing to eliminate range-anxiety often found with battery-electric vehicles,” commented Steve Burns, Founder and CEO of Workhorse Group Inc.  “We are extremely pleased to add BMW to our growing base of world class suppliers.”

About Workhorse Group Inc.

Workhorse Group Inc. is a U.S.-based original equipment manufacturer of medium-duty, EPA-approved battery-electric delivery vehicles and fully integrated truck-launched, FAA compliant unmanned aerial systems (UAS) delivery drones. The company is also a developer of a cloud-based, real-time telematics performance monitoring system that provides fleet operators ultimate energy and route efficiency.

Source: Workhorse Group Inc.

How it all started: The conception of Toyota Prius

On January 16, 1992, the Toyota Motor Corporation announced the Earth Charter, a document outlining goals to develop and market low emission vehicles.

In September 1993 Toyota R&D Executive Vice President Yoshirio Kimbara created G21, a committee to research cars for the 21st century. On February 1, 1994, the first official meeting of the G21 project team took place. The team determined the goal of G21 is to create a car that is resource and environmentally friendly while retaining the benefits of modern cars. The development effort was led by Takehisa Yaegashi, who was tasked with building a car that bridged the gap between electric and gasoline powered vehicles.

In 1994, Toyota executive Takeshi Uchiyamada was given the task of creating a new car that would be both fuel efficient and environmentally friendly. In late 1994, the G21 team designed a concept car with a hybrid engine for the 1995 Tokyo Motor Show. The vehicle was named “Prius,” the Latin word for “prior” or “before.” It was shown on October 27, 1995. In late 1996, test driving began.

1996 Prius Prototype . Image source Wikimedia Commons

After reviewing over 100 hybrid designs, the engineering team ultimately settled on a continuously variable transmission (CVT) design based largely on a 2000 TRW patent application, but many technical and engineering problems had to be solved within the three years that the team was given to bring the car to the Japanese market, a goal they barely achieved as the first Prius went on sale in December 1997. One major problem was the longevity of the battery, which needed to last between 7 and 10 years. The solution the engineers came up with was to keep the battery pack between 60% and 40% charged, proving to be the “sweet spot” for extending the battery life to roughly that of the other car components. A Toyota spokesperson stated that “Toyota chose this name because the Prius vehicle is the predecessor of cars to come.”

Battery pack from second generation Prius

Initially, in December 10 1997, first Prius went on sale in the domestic market that is Japan. At the time of launch, first generation Prius, was the world’s first mass produced gasoline-electric hybrid car. Later in 2001, more powerful version was introduced in United States Of America.

The Prius is sold in over 90 markets, with Japan and the United States being its largest markets. Global cumulative Prius liftback sales reached the milestone 1 million vehicle mark in May 2008, 2 million in September 2010, and passed the 3 million mark in June 2013. Cumulative sales of 1 million Priuses were achieved in the US by early April 2011,and Japan reached the 1 million mark in August 2011.As of April 2016, the Prius liftback is the world’s top selling hybrid car with 3.73 million units sold.

First generation Prius
Second generation Prius
Third generation Prius
1200px-Toyota_Prius_(IV)_–_Frontansicht,_19._September_2015,_Frankfurt (1)
Fourth generation Prius


Source: Wikipedia


EV’s production in India is all set to get boost from CECRI and CAEM

Thanks to Central Electrochemical Research Institute(CECRI) and Centre for Automotive Energy Materials (CAEM) that now India can produce Li-ion batteries instead of depending on imports. This is going to boost the Indian Electric Vehicle industry further apart from the FAME India Scheme introduced by govt of India.

Globally, there is an urgent need for the development of alternative energy sources, especially for the automotive sector, due to the alarming depletion of the fossil energy reserves. Lithium-ion battery has emerged as a promising candidate to alleviate this problem due to its attractive features viz high energy density (both volumetric and gravimetric), high current drain, high cycle life, low self-discharge, absence of memory effect, good low temperature performance.

Image for illustrative purpose only

Centre for Automotive Energy Materials (CAEM) has been recently set up at Indian Institute of Technology (M) Research Park, Chennai with a focus to start major R&D programmes on Materials and Components Technology for Electric Vehicle (EV) / Hybrid Electric Vehicle (HEV) applications. The Centre is developing Li-ion battery for EVs/ HEVs by setting up Research facility for Lithium-ion cells and battery packs at pilot plant scale. Lithium-ion battery technology is projected to be the leapfrog technology for automotive sectors to provide stationary storage solutions to enable the effective use of renewable energy sources. Giant automobile manufacturers like Ashok Leyland are already engaged in the Manufacture of EV based on Lithium-ion batteries (LIB’s) and CAEM has initiated the interactions to work closely with them to demonstrate ARCI’s in-house Li-battery technology for EVs.

For the Lithium-ion batteries, India’s market share is significantly high in the area of consumer electronics. It is expected to increase in the Electric Vehicle sector also. However, in India, till date, there are no manufacturers of Lithium-ion cells; It is hence comprehensible that there are no manufacturers of most of the raw materials for the batteries also. Keeping in view the rapid growth of the Automotive Industries and the need for the development of the material technology for sustainable transportation, CAEM has taken up a major project to develop Li-ion battery materials for EV/HEV by setting up the manufacturing of Lithium-ion cells and battery packs at pilot plant scale for automotive application. The project is planned to be executed in a twofold approach.

The following are the expected outcomes of the project:

  • Setting up a pilot scale facility for the fabrication of the Lithium-ion cell, and development of the technology for E-bus battery of capacity 330V, 200 Ah and batteries for E-cars
  • The Pilot plant facility will also cater to other capacity batteries required for E-scooter and E-car. This will meet the needs of the automobile industry in the country for reducing Green House Gas Emission and foreign exchange for importing the oil which is the Ultimate Goal of the project.
  • Electrode materials and other components for Li-ion battery (LIB) will be developed indigenously. This offers scope for the in-house development of tailor-made LIB for a wide variety of Niche applications.

In parallel The Central Electrochemical Research Institute (CECRI), Karaikudi in Tamilnadu, has set up the first indigenous Li-ion fabrication facility that has applications in electric vehicles, defence, solar powered devices, railways and other high end usages.

“It’s the first time that we will have our own technology and potential to produce Li-ion batteries domestically. This would help in cutting costs as well as our dependence on the foreign market,” professor Vijayamohan K. Pillai, CECRI Director, told IANS. CECRI is part of the Council of Scientific and Industrial Research (CSIR).

“In two months we will attain capacity to produce at least 100 batteries in a day at our lab,” he added.

India uses around 1 billion Li-ion.For now, 100 percent of Li-ion batteries or cells used are imported.China, Japan, South Korea, Taiwan and some Western countries are the major manufacturers of lithium ion batteries.According to experts, mass production of indigenous Li-ion batteries would reduce the cost manifold as compared to the imported batteries.”Imported batteries are very expensive. The domestic programme can bring the price down”.

CECRI has also invited investors for mass production. “Some investors have already shown interest. A Canada-based NRI is willing to install a plant in India. On June 3, we have (former DRDO chief) V.K. Saraswat visiting our fabrication facility. His visit gives hope for good investments,” Pillai said.