​At a time when the electrification of vehicles is becoming increasingly important, high-voltage systems are playing a crucial role. In an interview with high-voltage specialist Felix Thiel, we find out how the team at MVI AUTOMOTIVE in Oberschleissheim is continuously developing and advancing e-mobility for its customers.

The MVI development workshop, located in the north of Munich, recently underwent an upgrade in response to a surge in orders from automobile manufacturers. We covered this development in our February 2024 blog post titled ‘Workshop Upgrade’. Since then, the anticipated expansion for handling high-voltage systems has been successfully completed. As a result, the experts at MVI AUTOMOTIVE are now equipped to provide solutions not only for electric and hybrid vehicles but also for electric motorcycles,” explains Felix Thiel.

Thiel further adds, “The influx of orders was immediate and diverse, ranging from compact vehicle models to luxury limousines. We have already performed a significant amount of high-voltage (HV) work.” The seasoned HV expert also highlights a new addition to their equipment, “Thanks to our new ‘Electric Ant’, we can effortlessly transport storage units weighing up to 800 kg.” This enhancement significantly boosts their operational efficiency in handling heavy components.

Focus in the new service area
“We specialize on the one hand in upgrading and on the other hand in repairing high-voltage systems.” For the former, the storage units located in the underbody of the vehicle are removed and opened “Then you can look into the heart of the vehicle, so to speak, into the high-voltage storage unit, in order to make the necessary adjustments,” explains Thiel vividly. It is now a matter of replacing individual parts such as cell monitoring circuits (CSC) or monitoring the cell voltage in batteries (CPs) or battery management units (BMU), new connectors and much more. In short, if the hardware or software changes because it is updated or new, it is called an upgrade,” says the specialist.
“Nowadays, components are replaced rather than repaired,” says the former trained car mechanic. If components of the development vehicles are faulty, the removal and conversion work is carried out in the MVI development workshop. In addition, the electric motors known as “HEATs” are also regularly replaced in the electric workshop due to improvements in performance.

What conditions are essential for HV work?
MVI AUTOMOTIVE employees are trained to carry out “live working” (AUS) up to 1000 volts. Electric vehicles are currently designed from 400 volt powertrains up to 800 volts, offering more range through a faster charging cycle and less weight, because the higher the voltage, the smaller the cable diameter required. “The tools and equipment our employees work with are approved for 1000 volts and specially insulated – important to prevent short circuits,” and an essential criterion, according to Thiel, is “a special AUS work surface that must meet certain requirements in order to be able to carry out the conversion work.” The regulations include that there must be a separate area, no ESD floor, little pedestrian traffic and, ideally, an escape route. “These precautions are also in place here,” the expert confirms.
There are different levels of training that allow employees to work on high-voltage systems. In the case of de-energized vehicles, the entire team is authorized to work on them, as all members have completed the basic level 1 training. However, only those who have reached level 2 are allowed to de-energize the vehicle. At MVI AUTOMOTIVE, we continuously invest in the training of our mechanics to enable them to progress from Level 2 to Level 3. The team is also looking for experienced specialists who already have level 2 certification or even the highest level 3 to work on high-voltage storage systems. In addition to MVI’s general benefits, we offer our employees a wide range of training and further education programs to continuously expand and deepen their skills.

Innovative solutions for customer support such as containers for HV storage systems
In order to provide customers with even more comprehensive e-mobility support, the company has invested in a special container in which high-voltage storage units are stored. This customized container not only offers a secure storage environment, but also a range of safety precautions, including internal monitoring systems, theft protection and an integrated fire extinguishing system in the event of an emergency. “Continuous monitoring is ensured by a state-of-the-art alarm system, which includes both audible signals and a 24/7 manned control center,” Thiel informs us.
Batteries from an OEM are currently stored and can be retrieved by the customer at regular intervals. For longer storage periods, we carry out precise measurements to check the capacity and performance of the storage units.
Thanks to our efficient working methods and flexible logistics, we can ship or collect the high-voltage storage units within one day, packed in dedicated transport boxes.
A special tool enables the customer to view the workload in the workshop and coordinate orders accordingly. The MVI AUTOMOTIVE team is fast and reliable, something that customers also appreciate. Thiel explains one example with a smile: “There was a situation where a customer’s electric car broke down on the road. We reacted immediately, towed the car away and repaired the damage: Marten bite,” he laughs and says, “I guess they can work under tension too.” But as you can see, MVI AUTOMOTIVE is ready to help in any situation.

The MVI development workshop in the north of Munich is excellently equipped for future challenges.
With innovative solutions and a highly qualified team, they are ready to play an active role in shaping change in the automotive industry. Felix Thiel emphasizes the company’s forward-looking approach, the good dynamics in the team and its continuous development to meet the requirements of future developments.