E-Mobility Engineering

Additive Drives GmbH uses injection-moulded copper Additive Drives has developed an injection-moulded copper process for the next generation of electric-drive busbars, writes Nick Flaherty. The development combines the best of two worlds: specialised design and mass production. Additive Drives is using the process for busbars with printed, conventional or injection-moulded parts in copper and plastic. Both simple and highly complex components will be produced in high volumes of tens of millions per year. Copper powder is combined with an organic binder to work with existing injection-moulding machines.  A value of 100% International Annealed Copper Standard (IACS) electrical conductivity corresponds to 58 MS/m at a temperature of 20 C. After injection moulding, the processed copper achieves a conductivity of up to 01%. Other physical properties, such as density or thermal conductivity, are very close to those of conventionally drawn copper. For electrical machine designers, this process enables the integration of functional elements such as press-fit nuts, connectors or thermal sensors, as well as minimising volume and avoiding hotspots. The process can also add plastic parts and insulation with a rating up to a temperature of 240 C, as well as contacts coated with silver or nickel to reduce assembly steps and save costs. Initial studies suggest copper mass can be reduced by at least 40%, compared with conventional busbar designs. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #motormaterials #electricmotors #emotors #emobility #electricmobility #electricvehicles

Multi-chemistry batteries A little over a year ago, a BMW iX electric SUV fitted experimentally with a dual-chemistry Gemini battery pack from Our Next Energy (ONE) drove 978 km (608 miles) on a single charge – an impressive achievement for such a large, heavy car, writes Peter Donaldson. The Gemini battery features high power-density LFP cells and high energy-density, ‘anode-free’ cells. The robust LFP cells handle day-to-day driving up to 150 km, after which the more sensitive cells are switched in, adding 450 km of range, with the DC/DC conversion system transferring energy between them. In another example, Chimera Energy is developing a battery that features both lead acid and lithium-ion cells to produce an affordable battery with a better balance of performance and longevity than either chemistry can for cost-sensitive applications, such as electric quads and other off-highway EVs, static storage and even aerospace uses. Such dual- and even multi-chemistry batteries are a very attractive idea as, like any other hybrid, they promise to compensate for the weaknesses of each technology with the strengths of another. There is one obvious objection to the idea in that it seems a lot of effort to expend when the same result might be achieved by fitting separate batteries with complementary chemistries. However, using separate batteries brings its own challenges, as each one typically requires a BMS of its own, adding to the complexity of integration and control – possibly necessitating a third, supervisory BMS. It also tends to bring duplication of other components such as thermal management pipework and pumps, wiring and connectors. A further drawback of independent systems is their reduced flexibility in operation, as dynamic balancing of performance across chemistries is much more difficult, limiting overall optimisation. Inevitably, before integrated, multi-chemistry batteries can reach their hoped-for potential there are multiple technical hurdles of their own to be overcome. One of these is complexity in power management, particularly when it comes to balancing chemistries and designing appropriate switching topologies. Different chemistries have unique charge/discharge characteristics, energy densities and thermal behaviours, so creating a control system to transfer loads and charging currents among them dynamically and efficiently is challenging. Also, developing switching mechanisms that are reliable and not overly complex is critical to ensure seamless operation across chemistries and to minimise energy losses. Further, cells with different chemistries tend to work best at different temperatures, so devising a thermal management system that can avoid overheating and inefficiencies in the combined system is tough. Click here to read the full article ▶ https://lnkd.in/eydzcfrP #batterydesigns #thermalmanagement #evbatteries #batteries #batterycells #batterytechnology

Rising demand for mechanical insulation stripping of busbars Busbars can be found in a wide range of electric vehicles, from small passenger cars to large trucks. Different requirements, dimensions and geometries have to be considered in the manufacturing process of these vehicles. Busbar machines from WAFIOS Umformtechnik GmbH cover a broad product range. One process step is insulation stripping which can be completed mechanically or with lasers. Mechanical insulation stripping is the right choice for manufacturers seeking rapid cycle times and cost-effective production. WAFIOS busbar machines can be adapted to the individual requirements of a production process, whether short or long busbars, complex busbars and busbars with or without twisting shall be produced. The BMF series is particularly suited for the production of more compact busbars, such as those installed in vehicles that offer little space. Just like conventional bent parts, the busbars are manufactured in a 3D bending process. The patented WAFIOS tool technology makes very tight radii with a thin profile possible. In addition, the alignment of the busbar ends can be modified in a flexible way by twisting. At the same time, the patented rotary roller infeed unit, which is used in virtually all WAFIOS wire bending machines, offers maximum production speed. During production, only the lighter component is rotated, and not the bending head itself. Are you looking for a busbar machine that can handle extra-long busbars with a large conductor cross-section? The TWISTER² 25 and TWISTER² 35 are the answer. Originally intended for the tube-bending sector, the TWISTER² has been adapted for e-mobility. The result is a machine that can process busbar cross- sections of 300 mm² and lengths of up to 3,000 mm. The tools use the rotary-draw bending method from the tube-bending sector. They are very gentle on the material and prevent surface deformation, for example. At the same time, there is a sufficient bending moment available to bend busbars of up to 300 mm² over the long as well as the short profile side. Automation solutions for individual busbars and optimal production processes For the busbar bending machines, WAFIOS offers end-to-end automation solutions for additional or subsequent operations. These include punching various geometries, ultrasonic welding, feeding in and mounting stator connector parts, labelling the busbars and discharging onto workpiece carriers or transport belts in the correct position. This enables manufacturers to increase their productivity, improve quality and reduce the cost per piece. Click here to read the full article ▶https://lnkd.in/enQ-CH8f #automotive #electricvehicles #busbars #ev #emobility #electricvehicles

Evice Rolls-Royce Corniche Evice is using modern technologies and EV powertrains to improve some of the best cars ever built, starting with a beautiful Rolls-Royce Corniche, reports Will Gray. When it comes to pure, opulent luxury, there are few more iconic cars than those produced by Rolls-Royce in the 1970s and 80s. In an era defined by the growth of wealth and a desire for social standing, these were seen by many as the best cars in the world, the ultimate head-turning status symbols of riches and fortune. The stunning Corniche was immediately snapped up on its release by famous celebrities such as Paul McCartney, Frank Sinatra and Tom Jones, while David Bowie, Michael Caine, Elton John and Dean Martin all queued up on a two-year waiting list. The car’s starring role in countless films and TV series made it a true icon of the era. Now, beautifully aged into the realms of a modern classic, vehicles such as the Corniche still evoke fond memories of the past and are increasingly sought after by collectors. However, at a time when emissions restrictions are pointing them towards extinction, the only way they can live on is by adopting synthetic fuels or an electric powertrain. Evice is focused on the latter, but its ambitions go far beyond a simple conversion. “Our intent has always been to make a much-improved version of the original,” says company founder and CEO Matthew Pearson. “These were the automotive pinnacle at one time, and our aim from the start was to see them into the 21st century in a completely different light. “A lot of restoration and conversion companies talk about redefining what the car is, but that’s not what we’re aiming for. We are focused on looking at incredible cars that could potentially be made even better with electrification and taking away all the compromises that were made in the originals. “We want to create classic cars that have zero impact at the place they are used, but we also want to develop great technology that proves an electric future can be exciting and better than what we have come from. That’s how we ended up with the Rolls-Royce and Bentley aspirations, because we feel these classics are even better as electric cars.” The company’s three co-founders – CEO Pearson, COO Charlie Metcalfe and CTO Will Burdett – met at Bath University on a mechanical engineering course. They went their separate ways, working at different companies in different industries, including stints in the high-end EV conversion world, before reuniting to create their own car company. Click here to read the full article ▶https://lnkd.in/e23A5AHR #automotive #electricvehicle #ev #evpowertrain #electricpowertrain #electrification

We're excited to announce that registration for CWIEME Events (Coil Winding, Insulation, & Electrical Manufacturing Exhibition) Berlin 3-5 June 2025, is now open! Get your FREE TICKET today and start planning your visit. Who will you meet? You will connect with industry leaders from across the globe at CWIEME Berlin, through the industry's largest connections programme Connect @ CWIEME With 550+ exhibitors representing 45+ countries, this is your chance to meet with technical experts on a global stage. With your all-access FREE ticket, you will be networking with thought leaders, discovering cutting-edge technologies from top suppliers, and engaging with sustainability-focused exhibitors to find solutions that matter most to your business. GET YOUR FREE TICKET NOW! and experience the Global Home of Coil Winding ▶ https://lnkd.in/dC47h-fz #CWIEMEBerlin #CoilWinding #ElectricMotors #Transformers #Engineering #Berlin #Technology #Innovation #CWIEMEBerlin2025

Coreless technology shrinks current sensor MELEXIS has used a digitally controlled, coreless technology that shrinks the size of a current sensor, writes Nick Flaherty. The MLX91235 sensor eliminates the need for a ferromagnetic core, enabling the measurement of larger currents flowing through external primary conductors, including busbars. The MLX91235 is smaller than typical sensors and eliminates hysteresis-related measurement errors. The differential measurement of the magnetic field between two internal sensing elements provides accurate current feedback. With a 500 kHz bandwidth and 2 μs response time, the sensor is suitable for high-speed applications, such as motor-control and converter applications. It offers more precise and sophisticated compensation, resulting in a more accurate, smoother output. Calibration is configured via a standard, serial peripheral interface (SPI), allowing this in-situ via any microcontroller unit. Built-in, 16 bit, over-current detection (OCD) allows for asymmetric thresholds and includes two configurable ranges. It has a configurable detection time with a minimum duration of 2 μs and an optional debounce strategy, which helps to avoid false positives in harsher electromagnetic compatibility environments. The MLX91235 is ISO 26262-compliant as an ASIL B Safety Element out of Context. This goes beyond the ASIL B requirements with a built-in self-test (BIST) that can be triggered via the SPI interface, enabling the report of temperature, under-voltage and mechanical stress. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #electricmobility #electricvehicles #evmanufacturing #evtechnology #emobility #electrification

innolectric AG unveils CEC flexible charging platform innolectric has rolled out the Compact Efficient Charger (CEC) platform, designed to simplify and optimise the charging process for EVs. With its power density of 2.0 kW/L, the CEC is compatible with major AC and DC charging standards. It has a robust design (IP6K9K), operating at temperatures of -40 C to 65 C. It has compact dimensions of 460 x 460 x 93 mm and weighs about 19 kg. Tim Karcher, CEO of innolectric, said: “Our new CEC onboard charger platform brings together the needs and wishes of our customers, even if these are partly contradictory. “We have combined a class-leading power density with the already familiar scope of services of our OBCs: maximum flexibility in the installation position, integrated charging communication in accordance with current and relevant charging standards of the future, as well as the control of peripherals.” The charger is suitable for applications such as: heavy-duty, construction and mining machinery; municipal and agricultural vehicles; light and heavy-duty trucks; ferries and yachts; and stationary and mobile applications, such as refrigeration and ESS. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #evcharging #onboardcharging #charing #emobility #automotive #electricvehicles

Analysis finds Altilium’s CAM outperforms virgin mined materials Altilium Clean Technology has announced the results of research by Imperial College London, revealing that its recycled cathode materials (CAM) match and outperform virgin mined materials – a critical milestone in the bid to meet net-zero targets. Imperial College’s analysis of Altilium’s CAM confirmed improvements in purity, morphology and electrochemical performance, compared with commercially available materials. These benefits have the potential to deliver longer battery life, faster charging times and lower costs. This involved extensive electrochemical testing of coin cells and pouch cells made with recycled CAM produced at Altilium’s ACT1 facility in Devon. With a cycle cell capacity exceeding 150 mAh.g⁻¹, the materials significantly outperformed typical ranges for mined materials. Analysis of the recycled CAM samples also revealed significant advancements in particle size and distribution, contributing to improved stability and cycling behaviour. Crucially, minor changes observed during testing affirmed the chemical and physical robustness of the recycled CAM. Altilium says its proprietary EcoCathode process is capable of recovering over 95% of critical metals, including lithium, from end-of-life EV batteries. Altilium co-founder and COO, Dr Christian Marston, Co-Founder Altilium Clean Technology, said: “These results confirm the reliability and superior performance of Altilium’s materials, and validate our mission to build a UK champion for EV battery recycling. Recycled CAM not only aligns with global sustainability goals, but also offers improved technical performance at a lower cost, making it a game-changer for the EV industry.” Unlike virgin ores, which vary in quality and require extensive refinement to remove impurities, recycled materials are derived from standardised, manufactured batteries, reducing impurities and variability in metal composition. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #batterymaterials #evbatteries #batterymanufacturing #batterycells #batteryrecycling #batteryproduction

Littelfuse has unveiled the C&K Switches KSC2 KSC Dual Circuit Technology (DCT) series. The latest addition to its innovative tactile switch series offers a 3.5 mm actuator height, which is lower than the KSC4 DCT at 5.2 mm. This allows it to fit into tighter spaces, providing greater design flexibility. Combined with single-pole, double-throw (SPDT) functionality, the KSC2 delivers unmatched functionality in a compact, space-saving design. The SPDT configuration, which generates two independent output signals within a single switch, is said to enhance reliability and versatility, allowing active failure detection, complex control schemes and simplified circuit design. The KSC2’s compact profile is ideal for slim and compact devices where every millimetre matters, while the shorter actuator travel distance enables quicker signal registration and faster response times, enhancing device performance – critical for applications requiring high speed and accurate input. With robust IP67-rated sealing and SPDT functionality, the KSC2 is ideal for demanding environments where compactness, reliability and advanced functionality are paramount. “By offering a lower actuator height, we’re enabling designers to achieve greater precision and faster response in smaller form factors,” said Jeremy Hebras, vice-president of digital & technical developments in the electronics business unit at Littelfuse. “This addition reflects our commitment to advancing functionality while meeting the space-saving demands of today’s applications.” The KSC2 is designed for a variety of applications, including high-end consumer (power tools, lawnmowers and snow blowers), medical (electrosurgical instruments), industrial (elevators, smoke/fire alarm systems and automation equipment) and transport (automotive door handles and EV charging stations). Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #powerelectronics #charging #evcharging #electrfication #automotive #electronics

Thermal management In issue 17, we spoke with industry experts about the latest advances in EV thermal management technologies. Users of EVs of all kinds, and battery EVs in particular, want more range and/or running time, faster charging and greater assurance of safety. Thermal management is central to all these. We spoke with Marc P. at bp, David Nash at Dana Incorporated, Holger Schuh at Henkel, Roger Dr. Busch at MAHLE, Eric Dean at Parker Lord, Lewis Evans & Christian Marks at Senior Flexonics & John Williams at Aspen Aerogels to gauge the emerging technological solutions to these high-level requirements. Click here to read the full article ⚡https://lnkd.in/ekxSq8fn #thermalmanagement #bev #evthermalmanagement #batterymanufacturing #thermalrunaway #powerelectronics