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

Faster heavy EV production A purpose-built high voltage modular cable assembly (mCAY) has been developed to speed up production of heavy duty electric vehicles, writes Nick Flaherty. It can be said that many vehicle manufacturers focus on the direct costs of their solutions, without paying enough attention to indirect production costs such as assembly, test and production equipment, or even reworks. In fact these costs can be significantly reduced by considering requirements from production, and through the application of a modular approach, rather than a product-by-product approach. This is claimed by HUBER+SUHNER, which has expanded its high-voltage portfolio to deliver complete cable assemblies to customers. End-of-line testing is included within the assembly process, meaning once the mCAY solution has been assembled and tested together, the customer can install it immediately within commercial EVs. A web-based configuration tool allows developers to tailor the assemblies to their exact specifications with a mix and match approach to the cables, connectors and glands. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #heavyduty #electricvehicles #commercialvehicles #electricmobility #emobility #electrification

comemso electronics GmbH aims to simplify charging analysis comemso has launched comframe, a platform designed to simplify and streamline the analysis and testing of various e-mobility applications. “Our aim was to design the essential features in a way that allows beginners to start testing and analysing right away, and provides experts with detailed measurement and analysis capabilities,” said Anita Athanasas, CCO of comemso. “With comframe, we have succeeded in creating a solution that allows beginners to use extensive, pre-configured settings, while enabling experts to perform analyses down to the bit level of communication.” Intuitive configuration cockpits for EV, EVSE and Man-in-the-Middle tests allow for a quick, visual understanding of progress; currently for AC and DC-CCS charging. Clear visualisation of communication and power-path sequences simplifies complex processes for users. Graphical analysis tools provide immediate, in-depth analyses of error cases. Functions include: testing and analysis of EV and EVSE charging interfaces, according to IEC 61851-1, DIN 70121, ISO 15118-2/3 and ISO 15118-20; Man-in-the-Middle tests and data analysis for comprehensive interoperability examinations; support for new EVCA-Flex systems, as well as older comemso hardware generations; and the comemso CCS protocol stack for all applications, and as the basis for upcoming DIN and ISO test libraries. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #emobility #automotive #charging #evcharging #evtechnology #electricmobility

comemso electronics GmbH aims to simplify charging analysis comemso has launched comframe, a platform designed to simplify and streamline the analysis and testing of various e-mobility applications. “Our aim was to design the essential features in a way that allows beginners to start testing and analysing right away, and provides experts with detailed measurement and analysis capabilities,” said Anita Athanasas, CCO of comemso. “With comframe, we have succeeded in creating a solution that allows beginners to use extensive, pre-configured settings, while enabling experts to perform analyses down to the bit level of communication.” Intuitive configuration cockpits for EV, EVSE and Man-in-the-Middle tests allow for a quick, visual understanding of progress; currently for AC and DC-CCS charging. Clear visualisation of communication and power-path sequences simplifies complex processes for users. Graphical analysis tools provide immediate, in-depth analyses of error cases. Functions include: testing and analysis of EV and EVSE charging interfaces, according to IEC 61851-1, DIN 70121, ISO 15118-2/3 and ISO 15118-20; Man-in-the-Middle tests and data analysis for comprehensive interoperability examinations; support for new EVCA-Flex systems, as well as older comemso hardware generations; and the comemso CCS protocol stack for all applications, and as the basis for upcoming DIN and ISO test libraries. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #emobility #automotive #charging #evcharging #evtechnology #electricmobility

IONETIC slashes EV battery pack development time and costs IONETIC has unveiled Arc, which it refers to as a world-first, software-accelerated, AI-supported development system that delivers multi-million-dollar savings in battery development costs and halves time-to-market for custom packs. The company says Arc cuts the typical $30 million (£23 million) investment and four-year development cycle required for bespoke EV battery systems from Tier 1 suppliers by automating design and integrating pre-validated components into a fully end-to-end battery pack development system. James Eaton, CEO and co-founder of IONETIC, said: “As the push for EV adoption accelerates, OEMs need the right partners to bring competitive, electrified vehicles to market as fast as possible. Our Arc system allows us to provide OEMs with pre-validated, tailored solutions, enabling them to remove inefficient development processes, focus on vehicle innovation, and eliminate the usual bottlenecks of cost and time.” Arc rapidly optimises, conceptualises and brings to life battery pack design, facilitating significant time and cost reductions, using a network of AI-accelerated tools. Rather than requiring a large upfront investment and bespoke manufacturing lines, Arc uses an innovative, flexible manufacturing system, serving multiple customers without the time and costs typically required.  Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #batterytechnology #batterypack #batteries #electricvehicles #automotive #electrification

As the demand for sustainable transport solutions grows, understanding the differences between electric, hybrid, and hydrogen technologies is crucial. Each option has unique benefits, from emissions reduction to energy efficiency, but which one will dominate the roads of the future? Carpenter Electrification's latest blog compares these cutting-edge technologies and explores their potential to shape a greener tomorrow. https://hubs.li/Q02S7Wkk0 #SustainableEnergy #ElectricVehicles #HybridTechnology #HydrogenFuel #Electrification

🚀 We are thrilled to announce that E-Mobility Engineering has joined us as an official media partner for the CTI Symposium 2024 - Welcome aboard! In 2018 High Power Media launched E-Mobility Engineering as a quarterly magazine focusing on the electric and hybrid vehicle industry, providing concise coverage of the array of engineering challenges presented in this fast-growing market. Reporting independently on the engineering at the heart of electric vehicles providing unbiased commentary on full vehicles, hardware components, software programming, and other innovations and via interviews with leading EV/HEV engineers. Together, we’ll be sharing exclusive content, expert perspectives, and the most innovative trends as we drive towards this exciting event! 🚗 #CTISymposium  #CTI_Sym 👉The E-Mobility Engineering magazine will be available at the CTI Symposium 2024, offering the latest news and expert perspectives.

V2H & V2G bidirectional charging Nick Flaherty reports on the latest innovations in bidirectional charging and their ageing effects on battery cells. Bidirectional charging allows energy to flow back and forth between an e-mobility platform such as an EV and other systems, whether that is the electricity grid, other electric equipment or even other vehicles. However, the technology relies on specific chargers in the vehicle and the home. Recent vehicles are being equipped with bidirectional onboard chargers (OBCs), making use of the latest power devices with silicon carbide (SiC) and gallium nitride (GaN). The latest chargers are also adding bidirectional charging and standard CCS connectors, enabling new uses such as virtual power stations, but there are potential issues with the ageing of the cells in battery packs that needs more research. Vehicle-to-grid (V2G) supplies energy from the EV battery pack to provide stability for the grid. This is a challenge in many parts of the world, especially at the extremes of summer and winter, and requires synchronisation with the grid. One of the biggest challenges is providing electrical power quickly enough to avoid brownouts. Several countries, notably Australia, already use huge banks of batteries to respond rapidly to pending brownout conditions. EV batteries connected to the grid via bidirectional OBCs could contribute by delivering or consuming small amounts of energy to help balance supply under such conditions. Electric cars are expected to hold 305 GWh of energy in 2025 and 540 GWh by 2030, making them a significant source of power. Harnessing this in a virtual power plant (VPP) via vehicle-to-load (V2L) enables users to power electrical appliances from the vehicle. Utility vehicles are a prime example and can be used during recreation to power entertainment equipment, electric grills or even rice cookers while camping. Tradespeople and DIY enthusiasts can also use their electrical power tools in remote locations. This use case is currently more common in China and Asia-Pacific than in other areas. Vehicle-to-vehicle (V2V) charging is a longer-term feature requiring bidirectional support from OBC implementations, along with standardisation so that it is compatible across vehicle manufacturers. Vehicle-to-microgrid (V2M) applications see EVs interface with localised grid systems. The infrastructure typically includes renewable energy sources, storage systems and advanced metering. Vehicle-to-home (V2H) works with home storage in a number of ways, either charging from solar panels or feeding energy back to home storage systems or direct to the building. This latter case requires synchronisation. Click here to read the full article ⚡ https://lnkd.in/daQ6THci #charging #automotive #electricvehicles #v2g #ev #bidirectional

Charging forward with polyphase A polyphase wireless power transfer system has achieved a record 270 kW charging rate, writes Nick Flaherty. Researchers in the Power Electronics and Electric Machinery Lab at the Oak Ridge National Laboratory (ORNL) in the US successfully demonstrated the first 270 kW wireless power transfer to a Porsche AG Taycan at the end of a three year project with Volkswagen Existing wireless charging systems for cars are currently under development for up to 11 kW power levels with up to 92% efficiency, but are difficult to equip using conventional large, heavy wireless power transfer systems. The vehicle can’t support the charging hardware due to space, weight and volume limitations. In view of that the ORNL team used lightweight polyphase electromagnetic coupling coils with a diameter of 485 mm (just over 19 in) that provide higher power density in the smallest coil possible. This process is similar to the wireless charging of small consumer devices, but the unique geometry and design of the polyphase coils enable the transfer of much higher power levels using rotating magnetic fields generated by the coil phase windings to boost the power. The charging system was seamlessly integrated into the undercarriage of the Taycan. The wireless power transfer technology also includes protection systems that prevent exceeding voltage and current limits, overheating and short-circuiting. These systems can initiate shutdown procedures in the event of power interruptions or other unexpected conditions that would interfere with safe power transfer. The system can achieve a 50% increase in state of charge within 10 minutes with more than 95% efficiency. The power transfer was conducted over a 120 mm (4.75 in) gap between the ground and the coil mounted to the underside of the vehicle. “The receiver coil designed for the Porsche Taycan research vehicle can achieve 8 to 10 times higher power density compared to existing systems,” said ORNL’s Omer Onar, leader of the Vehicle Power Electronics group and lead researcher on the Porsche demonstration. “Per kilowatt, this is also the lightest charging system in the world.” The team had previously developed a 100 kW wireless system using a similar coil design, and ORNL and Volkswagen said they plan to continue working together to further develop the 270 kW charging prototype by developing it into a more cost-effective and manufacturable system. The 100- and 270-kW demonstrations mark the first time ORNL’s polyphase system has been tested on electric vehicles. “We’re also working with Volkswagen on developing a polyphase system for residential charging applications and collaborating on the development of a lightweight enclosure design that will improve mechanical, electrical, thermal and magnetic performance,” said Onar. Click here to read the full article ⚡ https://lnkd.in/eJAZ4dN8 #electricvehicles #automotive #ev #emobility #electrification #charging

💛 What is it about our electric excavators that we dig so much? 🖤 Is it the fact we’ve worked with them for more than 40 years? That they’re easier to maintain than their diesel counterparts? That they provide significant cost savings for customers? 🤔 We could keep going, but we have a better idea. Why don’t you check out the feature story about our electric excavators in the September issue of E-Mobility Engineering? We spoke with Rory Jackson about the history of Liebherr’s electric excavators and discussed exactly how these remarkable machines work – particularly in the harsh conditions found on mine sites! You can read the full article here: https://bit.ly/3A5XROn #liebherrmining #electric #excavators #zero #emissions