E-Mobility Engineering

Motor development and manufacturing Peter Donaldson details the many processes involved in creating new motor systems. As with any sophisticated industrial process, the development of motor systems for e-mobility is a complex and multi-stage endeavour, subject to rapid change under pressure, both to innovate and ramp up to high production volumes. The first stage is conceptualisation and definition, whereby key requirements are identified and the specifications of the motor are defined, based on the intended application, vehicle type, powertrain configuration and the regulatory standards that apply in the markets in which it will operate. Next comes design to flesh out the details of the motor geometry, including the stator, rotor, windings, housing and design software, and the subsequent electromagnetic and thermal simulations to optimise motor performance, efficiency and cooling requirements. Designs are then validated using finite element analysis (FEA) and computational fluid dynamics (CFD) simulations. Prototype development comes next, beginning with the fabrication of components such as stator and rotor assemblies, increasingly using rapid techniques such as 3D printing. Prototype motors are then assembled and put through initial bench testing to verify performance characteristics and validate simulation results. More comprehensive testing and validation follows, focused on the prototype’s performance, efficiency and durability, including dynamometer tests that evaluate torque, speed, power and efficiency under a range of operating conditions. Thermal performance testing assesses the new motor’s ability to operate reliably within the design temperature limits, while durability testing helps to evaluate its longevity and resistance to mechanical stress, vibrations and environmental factors. Click here to read the full article ⚡https://lnkd.in/esYeTn24 With a special thanks to: Dr. Jakob Jung at Additive Drives GmbH Rolf Blissenbach, Bernhard Schmitt at BorgWarner JAYDIP DAS at Carpenter Electrification Red Blaylock iNetic Ltd Barry Lee LH Carbide Adam N. Matrishvan Raval, Gary Stevens, at Turntide Technologies. James Byatt at TRAXIAL #motors #electricmotors #electricvehicles #powertrain #electrificaton #automotive

We're proud to partner with Thermal Management Expo for another year 🔋 Unlock the future of thermal technology! Thermal Management Expo Europe is coming to Stuttgart on 3-5 December 2024! Discover cutting-edge solutions for managing heat in high-tech industries, from EV batteries to renewable energy systems and electronics to semiconductors! Don't miss out on live demos and expert-led talks with representatives from organisations including Dovetail Electric Aviation, Milence, STIRWELD and Virtual Vehicle Research GmbH! Find out more and register free here: https://lnkd.in/eAHdus-b #thermalmanagementexpo #thermalmanagement #batterysafety #evbatteries #automotive #electricvehicles

1000 V stackable lithium-ion batteries Epsilor Electric Fuel has developed lithium-ion batteries that stack to provide 1000 V in military systems, writes Nick Flaherty. The COMBATT Military High Voltage Battery System is based on Epsilor’s NATO standard 6T battery modules, it provides a capacity up to 175 Ah and 4400 Wh. The COMBATT 6T batteries are currently undergoing the MIL-PRF-32565C US ARMY standardisation tests. These tests include bullet penetration, extreme temperature performance (up to 500 C) and long cycle life, ensuring reliability in the most demanding military environments. Both versions are designed to support defence vehicles, tactical energy storage applications and ground military robotics. A variant of the battery, the COMBATT ELI-52526-GM, provides 4400 Wh/175 Ah capacity at 25.2 V for electric vehicles that are used in the field. This is six times the energy capacity of lead acid batteries of a similar weight, and 50% more than any other 6T lithium-ion battery pack. The connected strings of 6T battery modules are controlled by a joint high-voltage Battery Management System (BMS), which monitors and controls each individual 6T battery. The cells are charged from a 30 VDC power supply or 28 V alternator with a current of 82 A, although the BMS supports fast charging at 130A through a high current charge regulator that supports high-power alternator feed, surges and differential battery state of charge. The cells charge at temperatures between -40 C to 55 C using an internal heater with a discharge operation between -40 C to 71 C, again provided by the internal heater. The battery packs can also be transported by air. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #batteries #electricvehicles #automotive #batterymanagmentsystems #bms #automotive

Bel Fuse Inc. converter sets ‘new benchmark’ Bel Fuse is launching the 350DNG40-12-8, a 2nd-generation, 4 kW, liquid-cooled DC-DC converter. Operating from 240-450 VDC input voltages, the converter delivers up to 4000 W of output, and it can efficiently power low-voltage accessories in hybrid and electric vehicles. Built with full, galvanic isolation between input and output, it is embedded with a range of protection features that enable dynamic flexibility with load or input changes, ensuring high reliability in unpredictable environments. The converter features a CAN bus serial interface, and IP ratings IP67 and IP6k9k, making it ideal for construction equipment, underground mining applications, on- and off-highway vehicles, and marine equipment. Bel Fuse offers additional optional Unified Diagnostic Services (UDS) functionality, including CAN FD and cyber security. The product has obtained the e-Mark Certification. “Our new converter sets a new benchmark in power solutions for hybrid and electric vehicles with its advanced design, high reliability and flexibility, ideal for demanding industries like construction, mining and marine applications,” said Frank Vondenhoff, global director of e-mobility, product & business development. “With features like CAN bus integration and enhanced security options, we’re helping to meet the evolving needs of manufacturers and operators while maintaining strict regulatory compliance.” Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #emobility #electricvehicles #automotive #electrification #converters #electricmobility

TLX to exhibit modular valves at EV Tech Expo TLX Technologies, LLC is set to launch the first two components in its new family of modular valves at Electric & Hybrid Vehicle Technology Expo, held on October 8-10 in Detroit, US. Uniting critical performance characteristics and flexibility, TLX’s new 4-Way and 3-Way Switching Valves give OEM and system design teams thermal-management controls that suit multiple vehicle platforms. These high-flow valves deliver near-zero cross-flow leakage, reducing the number of challenges faced by design teams when developing a thermal-management system with the desired efficiency and flow-control characteristics. Two important features help to reduce a vehicle’s overall energy consumption to improve mileage or range, regardless of fuel type. First, the valves do not require constant power to maintain a commanded position and, second, their efficient fluid flow path minimises pressure drop, allowing the vehicle’s coolant pump to support the system’s fluid-management requirements with less power. TLX’s new modular valve family has the flexibility to suit vehicle platforms with different communication protocols, operating voltages and port size requirements. They support both 12 Vdc and 24 Vdc operation, and either PWM or LIN. Design teams can choose nearly any port size up to 25.4 mm without any changes to the valve body, flow path or drive system. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #thermalmanagement #electricvehicles #evtechexpo #automotive #emobility #electrification

Machine learning to reduce EV cost Machine learning is being used to improve the quality of laser welding systems and powder metal 3D additive manufacturing, writes Nick Flaherty. Laser welding machine maker TRUMPF is working with software developer SiMa.ai to develop lasers with artificial intelligence (AI). The goal is to equip several laser systems of TRUMPF with AI technology in the near future. This includes systems for welding, cutting and marking, as well as powder metal 3D printers. “AI has high strategic relevance for TRUMPF. Our expertise in laser processes and manufacturing helps us to develop smart software for production purposes,” says Richard Bannmueller, CTO of TRUMPF Laser Technology. The system will use the SiMa.ai machine learning system on chip (MLSoC), which run the ML applications entirely on chip. By doing so, this provides a tenfold increase in performance and energy efficiency for both computer vision and generative AI. The MLSoC AI chips will be integrated directly into the laser systems to use AI algorithms to monitor the quality of the laser welding process in real time and evaluate more than 3000 images per second. In electric car production, for example, the real-time quality inspection during laser welding with the help of artificial intelligence (AI) is expected to replace separate and complex testing procedures. Battery manufacturers will also be able to increase the quality of their production in real time and reduce the reject rate which could ultimately lower the price of electric cars for consumers. “The rapid acceleration of AI innovation is reshaping how humans can use emerging technology alongside TRUMPF’s highest level of process understanding, which is enabling AI solutions that drive the industry forward,” says Harald (Harry) Kroeger, head of sales and president of the automotive business at SiMa.ai. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #electricvehicles #automotive #ai #additivemanufacturing #ev #electrification

A cool idea for a DC-DC Vitesco Technologies has boosted the performance of its fifth generation automotive DC-DC converter, incorporating a move from liquid to air cooling, writes Nick Flaherty. This Vitesco Gen5+ DC-DC converter uses 650 V CoolGan transistors from Infineon Technologies to achieve an efficiency of over 96% by increasing the switching frequency from 100 kHz to 250 kHz with an energy density of 4.2 kW/l. Using gallium nitride CoolGaN transistors at 250 kHz enables lower switching losses, even in hard-switched half-bridges, with minimised thermal and overall system losses. The GaN devices have a lower on resistance of 50 mΩ compared with the previous design and the design handles a maximum constant of 30 A and a peak current of 60 A at a voltage of 850 V, even though the devices are rated for 650 V. A chip package with the cooling on the top, called TOLT, allows air-cooled designs that eliminate the need for liquid cooling and reduce the overall system costs and energy density. “The ultimate value of GaN is demonstrated when it changes the design, as in this example of moving from a liquid-cooled system to an air-cooled system,” said Johannes Schoiswohl, senior vice-president & general manager, GaN gystems business line head at Infineon. In an automotive application the DC-DC converter is connected to an 800 V battery pack to provide 12 V power for headlights, interior lights, wiper and window motors, fans; and at 48 V, pumps, steering drives, lighting systems, electrical heaters, and air conditioning compressors. The smaller size that comes from air-cooling rather than liquid cooling allows the converters to be flexibly positioned in the vehicle. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #powerelectronics #automotive #electricvehicles #ev #batteries #evbatteries

We're delighted to partner with the 5th Future Battery Forum🔋 which takes place on November 5-6, 2024 at ECC Berlin + online. The conference is staged under the motto “Accelerating Europe’s battery industry: Innovative. Sustainable. Stronger together.” With top-class speakers from industry and politics who will shed a light on these focus topics: Market strategies and policies, Manufacturing and gigafactories, Battery chemistry and design, xEV and stationary applications, Lifecycle and sustainability, Battery workforce. Besides keynotes and tech talks, the focus is on interactive formats like panel discussions, workshops, deep dives and excursions to industry sights. The networking highlight is the evening reception and party on the first conference day. Over 100 exhibitors will showcase the latest technologies and solutions for the battery industry. For further information on attending the event click here 🔋https://lnkd.in/eVxyCWx #futurebattery24 #batteries #electrification #electricvehicles #automotive #batterytechnology

The Battery Show Europe Show Report This year highlights of this major event included advanced manufacturing and developments in easing the dismantling of battery packs at the end of their first life. Click here to read the article ⚡ https://lnkd.in/eegTUk3q With a special thank to experts who contributed to the article - Philipp tho Pesch at Henkel Michael FIrl at Electro Static Technology (AEGIS® Shaft Grounding Ring), an ITW Company Dr. Hannes Schmüser at Dürr GROB-WERKE GmbH & Co. KG Manz AG Pravin Sievi at Scansonic MI GmbH Joerg Schormann at VOSS Dr.-Ing. Hannes Weinmann at Lead Intelligent Equipment Marc-André Grünewald at Handtmann Systemtechnik GmbH & Co. KG Ferdinand Heindlmeier at Roding Automobile GmbH Gian Carlo Tronzano at Comau Philipp Kowarsch at TE Connectivity Rimac Technology Boris Meisterjahn at Kautex Textron #batteries #evbatteries #batterytechnology #batterysafety #batterymaterials #electricvehicles

With one week to go before The Battery Show, we're getting excited to learn about the new products hitting the market! Comment below to let everyone know what you'll be showcasing along with your booth number. See you in Detroit! #thebatteryshow #batterytechnology #batterymaterials #batterysafety #electricvehicles #automotive #evtechexpo