E-Mobility Engineering

Battery tech for heavy duty applications With applications ranging from trucks to mining equipment and excavators, vehicle assemblers have a wide pool of requirements, as Nick Flaherty reports Flexibility is a key requirement for heavy-duty electric vehicle (EV) applications. These vehicles are based on existing chassis designed for diesel engines, so battery packs with various chemistries have to be manufactured to fit a wide range of form factors. With all the different battery cell formats for different chemistries, from cylindrical to prismatic, and varying safety requirements, there are many design tradeoffs. These designs cover commercial trucks from light Class 3 to heavy Class 8, as well as buses, and they need a standard connector for the charging system. The Megawatt Charging System (MCS) is being rolled out to enable them to charge in a wider range of places, rather than being limited to the depot because they use a proprietary system connector. Heavy-duty applications also include mining and drilling machines, which have varying ways of providing power, from long cables and overhead power gantries to swappable battery packs. Lithium-ion cells with nickel, manganese and cobalt (NMC) currently have the highest power commercially available, with capacity of 150-270 Wh/kg. Lithium iron phosphate (LFP) cylindrical cells have a lower energy density, of 90-160 Wh/kg at cell level, but their inherent safety, avoiding thermal runaway, means the pack can be made lighter than an NMC one. This increases overall energy density, especially as there are hundreds of cells in a heavy-duty application. Lithium titanate oxide (LTO) cells are also used for heavy-duty applications, particularly as they operate at low temperatures down to -30 C without the safety concerns of lithium-ion cells. They have a lower typical power density of 50-80 Wh/kg but the supply of the prismatic cells is more limited. Click here to read the full article ▶https://lnkd.in/e9GtAsY3 We would like to thanks the experts who helped research this article: Dr John Warner at American Battery Solutions Inc. Felix Nelius, Kevin Dahlberg & Martin Klein at Freudenberg e-Power Systems Images courtesy of: Sandvik Alpha Motors Atlas Copco #batteries #heavydutyvehicles #lithiumion #offhighway #thermalrunaway #battery

Stackable connectors that simply snap in place ENNOVI has developed a stackable, multi-row, board-to-board (BTB) automotive connector that snaps together without soldering, writes Nick Flaherty. The ENNOVI-MB2B system uses a proprietary ‘snap-in biscuit’ design, which allows multiple connector units to be stacked together without soldering, and it is reliable enough to use in EVs. The design enables different pin count requirements to be accommodated via the same basic interconnect without any extra expense or engineering effort. The BTB connectors are based on ENNOVI’s patented, 0.4 mm miniPLX press-fit terminals, which are made from a copper alloy that exhibits low levels of contact resistance at under 1 mΩ. These have an insertion force of under 70 N and a ‘push-out’ force of over 15 N. Each pin has a 3 A current carrying capability and can be covered with ENNOVI’s IndiCoat plating technology to mitigate the build-up of tin whiskers, which can cause short circuits. The coating extends operational lifespan. ENNOVI-MB2B connectors come in board-stacking heights of 7-30 mm for Electric Power Steering (EPS) and Electronic Control Unit (ECU) functions in EVs. The connectors can have one to six rows, with up to 30 contact terminals being incorporated into each one. Conforming with automotive performance requirements, these rugged products can withstand high humidity levels (eight-hour cycling up to 10% RH), mechanical shock (35 g for 5-10 ms across 10 axes) and vibration (eight hours per axis). A working temperature range of -40 C to 150 C is supported. “Being able to fit enough interconnect terminal pins into a small space while not having any excess is a priority for clients [and] keeping total cost of ownership down is vital,” says Ralph Semmeling, product portfolio director at ENNOVI. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #electricvehicles #emobility #automotive #powertrain #evs #electricmobility

Sealing cell module controllers using the CIPG process   bdtronic GmbH and Dr. Hönle AG UV Technology have teamed up to develop a solution for dispensing and curing liquid gaskets for cell module controllers using the CPIG method. Battery sensors play a crucial role in controlling and managing the performance and safety of EV batteries, monitoring temperature to voltage. During their production, highly viscous liquid sealants are used to protect the sensitive electronic components from dust, road salt and moisture, as well as temperature-related stress, physical shock and vibrations. These liquid sealants are typically identified as cured-in-place-gaskets (CIPG). The collaboration between bdtronic and Hönle has created an inline, five-step process for CIPG dispensing and curing. In the first step, the component contours are pretreated with atmospheric pressure plasma to achieve better adhesion of the sealant. In the second and third steps, the highly viscous CIPG is applied in contours. In the fourth step, curing is carried out using a Hönle UV curing system. Step five involves the optical inspection of the finished part to ensure the highest level of quality and consistency. “To achieve the best possible process, it is essential to work closely with the customer and all involved technology providers from the very beginning,” says Fabian Tremmel , head of engineering dispensing at bdtronic. “Our decades of experience in UV curing, and our uniquely extensive portfolio of LED-UV and UV systems allow us to quickly find the optimal solution for the customer,” says Mina Kamal, sales engineer at Hönle. The production line delivers a high-quality battery sensor seal every 13 seconds – a small but significant step on the path to e-mobility. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #batteries #evbatteries #batterysafety #thermalrunaway #thermalmanagement #batterytechnology

Cooper Standard debuts eCoFlow Switch Pump to simplify thermal management Cooper Standard has debuted the first member of its new eCoFlow product line. The eCoFlow Switch Pump, created in partnership with Saleri Group, offers the features of an electric water pump and an electrically driven valve in a single, integrated, coolant-control module. Available for all powertrains, this scalable fluid-control technology enables flow switching, splitting and regulating, which are especially needed to address the complex glycol thermal management needs of fully electrified or hybrid vehicles. “Our eCoFlow Switch Pump is a first-of-its-kind solution that enables customers to reduce the complexity of the thermal management system within their vehicles while improving overall system efficiency,” said Christopher Couch, president, fluid-handling systems and chief technology officer, at Cooper Standard. “Beyond the significant system savings, our solution provides customers with options to potentially reduce battery cell needs for their target vehicle range, which helps improve the vehicle’s overall carbon footprint.” The eCoFlow system makes the thermal management system more efficient by eliminating the pressure drop and waste encountered from traditional pumps and valves. Its improved design offers smoother flow transitions to help avoid pressure pulsations and spikes, which can lead to system noise, and it takes up half the space of the traditional components it replaces. A single electrical connection manages the system’s pumping and advanced fluid-control functions, eliminating the need for additional connectors, wire harnesses and vehicle input/output channels. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #thermalmanagement #electricvehicles #automotive #emobility #electrification #ev

AZL Aachen GmbH | Excellence in Lightweight Production invites firms to join rotor sleeves project AZL Aachen has announced a Joint Partner Project, focusing on the technology for reinforcing electric motors with fibre-composite reinforcement sleeves. The nine-month scheme will investigate current and future applications for electric motors, their requirements for armouring sleeves and provide technological insights. Interested companies can join the consortium, which includes Kümpers, Rassini and Schunk Kohlenstofftechnik, until the kick-off on September 12. The project, Rotor Sleeves for Electric Motors: Potentials for Composite Materials and Technologies, aims to address the growing demand for more efficient, powerful and compact motors. Composite rotor sleeves offer very high stiffness, low density, almost zero thermal expansion and favourable electromagnetic properties. They are expected to expand into mass applications for EVs, power tools, machine tools and electric aircraft. “As a manufacturer of composite materials, we develop and produce customised towpregs and prepreg UD [unidirectional] tapes for a wide range of applications. With increasing demand for efficient electric motors, the importance of rotor sleeves in mass production has increased, which achieve a very high level of performance, particularly when processed with towpregs. “The AZL Joint Partner Project is a promising opportunity to gain impulses for the further development of our material and market expertise… we look forward to expanding our network and discovering new solutions,” says Dietmar Hoffstedde, expert for composite towpregs & prepregs at Kümpers. AZL will bring together experts from across the value chain to investigate current and future applications, analyse requirements, and assess the impact on design, material selection and production concepts. Throughout the project, participants will gain a comprehensive understanding of rotor sleeve technology and its applications in electric motors. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #electricmotors #evs #electricaircraft #evmotors #electrification #emobility

AEHRA fuses beauty and innovation in two new EVs   AEHRA has revealed two new electric vehicles: the Impeto SUV and the Estasi Sedan. The company has also submitted a €1.2 billion development plan to the Ministry of Industry and Made in Italy for the construction of a state-of-the-art manufacturing facility. AEHRA’s philosophy is to fuse cutting-edge EV technology with breathtaking automotive art, with a focus on driving pleasure and sustainable mobility. The boldly designed Impeto SUV takes its name from the emotion ‘impetus’, celebrating a surge of creative energy, while that of the Estasi sedan reflects the emotion ‘ectasis’, the intense rapture from contemplating an object’s beauty. The two models will enter production in mid-2026. AEHRA founder and CEO Hazim Nada said: “We are delighted to unveil the names of the first AEHRA models, the Impeto SUV and the Estasi sedan. These highly conceptual vehicles represent an expression of pure Italian automotive art that is, in our eyes, an unprecedented fusion of beauty and innovation. “This provides further validation of AEHRA’s mission to redefine ultra-high premium, sustainable mobility by exploiting the very latest engineering, battery and manufacturing technologies.” The manufacturing campus will be located at Mosciano Sant’Angelo in the Abruzzo region of northeast Italy. About 540 new jobs will be created at the facility and an additional 110 roles in Milan, where the company’s HQ is based. AHERA has been invited to a key summit on the future of the Italian and European automotive industry at the Ministry of Enterprise and Made in Italy on August 7 in Rome. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #automotive #electricvehicles #evs #evmanufacturing #electrificaton #emobility

AkzoNobel protects batteries with one-spray powder coating AkzoNobel’s Resicoat brand has developed an innovative powder-coating technology that provides improved electrical protection for EV battery systems in just one spray. There is growing demand in the EV market for coatings with a high dielectric strength to help increase the safety of battery systems. Available in China, the new technology is suitable for battery system parts such as cooling plates, side plates and battery covers (enclosures). “We’ve developed innovative technology, which addresses a clear need within the industry and helps to improve safety,” says Jeff Jirak, director of AkzoNobel’s powder coatings business. “It’s an important breakthrough, which means customers no longer have to spray twice or more to achieve the right thickness for providing high dielectric strength.” The technology provides resistance against thermal shock, water immersion and chemicals. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #batteries #batterysystems #evbatteries #batterysafety #batterytechnology #batterymanufacturing

The Battery Show and Electric & Hybrid Vehicle Technology Expo is the leading meeting place for the advanced battery and H/EV technology community. With 1,150+ industry suppliers showcasing their latest innovations, networking opportunities with 19,000+ industry peers and 235+ expert speakers exploring the latest developments at the largest advanced battery conference in North America, this is an event not to be missed! Registration is now open and we’re inviting you to join us as we explore groundbreaking innovations, network with industry leaders, and share key insights. Stay tuned for exclusive coverage and updates! Register Now ▶ https://lnkd.in/dJh7z6Qk #batteryshow #evtechexpo #electricvehicles #batteries #batterytechnology #automotive

Parker Hannifin unveils thermally conductive gap-filler pads Parker Hannifin Corporation, a manufacturer of motion and control technologies, has introduced its THERM-A-GAP PAD 30 for EV battery packs. The thermally conductive gap-filler pads fit seamlessly into robotic assembly processes typical of the automotive sector, offering exceptional performance and conformability at a competitive price. During assembly, vision sensors can see the pads, which enables effective quality control and fast production. The pads release effortlessly from their liner for pick-and-place robots, making them ideal for high-volume applications, and they come in specially designed packaging to ensure safe shipment. THERM-A-GAP PAD 30 provides a soft (34 Shore 00) solution with 3.2 W/m-K of thermal conductivity and extremely low outgassing, ensuring an effective thermal interface between heat sinks and electronic devices where there are uneven surfaces, air gaps and rough surface textures. The supporting electrical properties of this RoHS-compliant pad include: 5.9 kVac/mm dielectric strength (ASTM D149 test method); 1013 Ωcm volume resistivity (ASTM D257); 7.7 dielectric constant at 1,000 KHz (ASTM D150); and 0.001 dissipation factor at 1,000 kHz (Chomerics CHO-TM-TP13). Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #thermalmanagemnt #evbatteries #batterysafety #automotive #batteries #emobility

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