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

Onboard chargers In this article learn how designers are making OBCs more powerful, faster and lighter. Key topics in the article include… ⚡ OBC topologies – designs to support increased power ratings and fast charging ⚡ Classical boost PFC, dual-boost PFC, or totem-pole PFC ⚡ The challenge of increasing power density to minimise the size of the OBC ⚡ LLC topology to reach the highest conversion efficiency #onboardchargers #charging #powerelectronics #powerconversion #semiconductors #automotive Click here to read the article 🔋https://lnkd.in/duFzkNY2 #charging #evcharging #electricvehicles #emobility #automotive #electricmobility

Scalable approach speeds up capacitor design TDK has developed a standardised, modular, DC link capacitor design for traction inverters, writes Nick Flaherty. The xEVCap is built from modules connected in parallel to provide specific capacitances for powertrain inverters in passenger cars, commercial and off-highway vehicles. The scalable approach helps inverter designers meet varying capacitance and current requirements at lower volumes while saving time. The use of standardised capacitor modules also reduces costs, minimising stock variety. The xEVCap has two connection styles: the B25654A*001 has lead wires for soldering to busbars or PCBs; the B25654A*002 has flat terminals for welding or screwing to busbars. The mechanical versions are 85 x 47 x 40.5 mm, 97.5 x 35.5 x 42.5 mm, and 109 x 47 x 40.5 mm. Rated voltages include 500 V, 650 V, 850 V and 920 V. Depending on the rated voltages, the capacitances range from 60 µF to 270 µF. All of the xEVCap modules are included in TDK’s CLARA tool, which simulates the components electrically and thermally under various conditions. Applied voltage can exceed rated voltage for a limited time to give overhead for the design. For example, the 850 V types can withstand 890 V for 100 hours at 105 C and surge voltages up to 1200 V. Rated currents range from 35 A to 60 A (at 10 kHz) with ESL values of 14 nH or 17 nH (at 1 MHz). The operating temperature range for each module is -40 C to 105 C. The capacitance range complies with automotive standards AEC-Q200 rev. E and IEC TS 63337:2024. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #electricvehicles #automotive #offhighway #emobility #powertrain #powerelectronics

Yokogawa releases WT1800R high-performance power analyser Yokogawa Test & Measurement Corporation has released its WT1800R high-performance power analyser to boost the efficiency of complex measurements for new energy applications. The WT1800R is the only instrument in its class that guarantees a power accuracy of 0.05% of reading plus 0.05% of range, says Yokogawa, and it is capable of harmonics analysis up to the 500th order of a 50/60 Hz fundamental frequency. With simultaneous, 16 bit measurements on up to six input channels at 2 MS/s, a wide range of display and analysis features through an enhanced display, and PC connectivity, the device is suitable for a broad range of power efficiency and harmonic analysis requirements. Engineers can perform field-oriented control measurements, such as Vd/Vq and Id/Iq, and store the data directly to a network drive. Measurements can also be combined with results from other instruments. The WT1800R power analyser was designed to support the development and production of high-efficiency new-energy technologies, combining measurement results with waveform-capturing instruments through the IS8000 software. Whether analysing multi-phase inputs during motor and drive design, or meeting the stringent efficiency standards of photovoltaic inverters, the WT1800R provides the versatility to help engineers bring their product concepts to market with an easy to read colour scheme. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #emobility #electricvehicles #automotive #electricmobility #batterytesting #emobility

innolectric AG presents reliable charging to international standards With its new DC Charging Controller, innolectric enables fast charging according to CCS1, CCS2 and NACS, and it is now available in higher volumes. The innolectric D3C is designed for vehicles operating in challenging environments and requiring high performance. The D3C provides all the functions required for charging via the vehicle CAN, including plug detection and locking, temperature monitoring and contactor control. The module has its own stack for charging communication, which enables continuous maintenance and customer updates. The DC charge controller can be customised to meet requirements. This includes adapting the signal to the desired application and adapting the communication interface to requirements. The standard housing is robust and can be used in demanding applications. The module measures 197 x 154 x 44 mm and weighs 0.9 kg. Integration into custom housings or module solutions is also possible. The module has proven itself in extensive field tests and series production has started. It also supports standards IEC 61851, DIN SPEC 70121 and ISO 15118-20. Tim Karcher, CEO of innolectric, said: “The possible applications are diverse; from maritime use to intralogistics in industry to use in apron vehicles on the tarmac. The positive feedback from our first customers confirms that fast charging is becoming more important and the D3C is convincing.” Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #charging #evcharging #automotive #fastcharging #electricvehicles #emobility

End-of-line battery testing Insight into end-of-line battery testing End-of-line (EOL) testing for EV battery packs is a critical step in ensuring their performance, safety and longevity. In this article we explore the complexity of this form of testing. Key topics in the article include… 🔋 Safety features – mitigating risks such as thermal events and electrical faults 🔋 Storing and analysing data – the core of any modern EOL testing system 🔋 Industry 4.0 and predictive maintenance – critical tools to minimise downtime in production, machine learning (ML) and big data management 🔋 Optimising throughput - striking the balance between thoroughness and speed 🔋 Accuracy and repeatability - Ensuring the accuracy and repeatability of these tests is critical to delivering consistent, reliable results Click here to read the article 🔋https://lnkd.in/esX7hmHN #batteries #batterytesting #testing #emobility #data #EOL

E-bikes gain BMS based on 100 V Gan devices Innoscience Technology has launched a battery management system (BMS) based on 100 V gallium nitride (GaN) devices for electric three-wheelers and e-bikes, writes Nick Flaherty. The VGaN devices are connected by a common drain for bidirectional switching of battery charging and discharging, reducing on-resistance to 3.2 mΩ. The INV100FQ030A 100 V VGaN IC supports two-way pass-through, two-way cut-off and no-reverse-recovery modes of operation, and it has a low gate charge of just 90 nC in a package measuring 4×6 mm. The device does not have a parasitic body diode, which allows the bidirectional control and can replace two traditional MOS silicon MOSFETs. Innoscience has developed a 48 V /180 A demonstrator of a BMS using the INV100FQ030A GaN transistor, packaged in a FCQFN top-cooled package. No heat sink is needed as the maximum temperature rise is below 50 C. The 16-string charging and discharging battery protection system uses the controllable, bidirectional conduction and cut-off features in the VGaN device, enabling four operational states: normal charging and discharging; charging protection; discharging protection, and sleep mode. “With 16 V GaNs, we can replace 18 pairs of silicon MOSFETs (36 in total), significantly reducing both the board area and system-loop impedance. This optimisation not only enhances performance and reduces system size, but also drives down the overall system cost, making it a more efficient and cost-effective solution for battery protection systems,” said Dr. Denis Marcon, general manager of Innoscience Europe. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #batterymanagement #bms #batteries #emobility #ebikes #electricmobility

Ilika tests 10 Ah cells to hit Goliath D6 milestone Ilika plc has reached its D6 milestone by testing 10 Ah cells in its Goliath solid-state batteries for electric vehicles. The modelling of a Goliath-based battery pack for EVs is under way by UK company Balance Batteries. Early results show the weight of the battery pack can be reduced by up to 100 kg on the basis of Goliath’s benefits, compared to a current SUV lithium-ion model of the same energy. Ilika is now progressing with development towards a D7 design freeze, which it expects to achieve in Q1 2025. This will form the basis of a release of 10 Ah prototype cells to customers, called the P1.5 prototypes; an upgrade of the 2 Ah P1 prototypes released in July 2024. The timing of the P1.5 release will be driven by completion of testing of a batch of batteries based on the D7 design by Q2 2025. The 2025 development roadmap will then extend to a D8 design freeze, which is also expected in Q1 2025, and then to the crucial Minimum Viable Product stage, targeted for the end of 2025. Ilika CEO Graeme Purdy said: “Meeting our D6 development milestone on schedule is a key marker to ensure we are progressing towards an MVP that meets or exceeds customer expectations. “Safety is a key differentiator for solid-state technology in the EV market, but also differentiates Ilika versus its solid-state peers as it seeks to lead the sector on this point… Ilika’s technology is a step closer to market readiness and commerciality.” Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #batteries #evbatteries #automotive #electricvehicles #batterytechnology #batterymaterials

Battery dielectric protection In this article we examine the multi-function dielectric materials that are critical in EV battery systems. Key topics in the article include… ⚡ Dielectric strength – reducing the risk of electrical breakdown with effective materials ⚡ Dielectric and thermal combined – playing a crucial role in safety and efficiency ⚡ Environmental stress – choosing the right dielectric material for specific environmental conditions ⚡ Complexity in flammability - dielectrics that meet stringent fire-safety standards, such as UL 94 and IEC 60695 ⚡ Testing, validation and ageing – ensuring reliability and performance of materials We would like to thank the following for their help with this feature: Germaine Mariaselvaraj at H.B. Fuller Andrew Richenderfer at The Lubrizol Corporation Jacob Collison at PPG Jeffrey Peet & Fei Wang at Saint-Gobain Tape Solutions Click here to read the article ⚡ https://lnkd.in/dYj-aErw #dielectric #batterysafety #batteries #thermalmanagement #emobility #battery

Donut Lab claims new platform builds faster, cheaper, better EVs Donut Lab has taken a new approach to building electric vehicles with a development platform that offers a library of inter-compatible components that can be used to produce supercars, buses, UVs or SUVs in record time, it says. The company claims the vehicles made on the platform offer better performance, and are lighter and more affordable. One of the platform’s main benefits is its scalability to suit a variety of applications, such as hypercars, helicopters, robots and even space mission ATVs. “Verge Motorcycles TS is the world’s most advanced electric motorcycle. When developing it, we learned how difficult and slow it is to build EVs using traditional mechanisms. The reason for this is that vehicles are built with components from different equipment manufacturers and are not designed to work together – integration work always takes up most of the time. We decided that if we were able to solve this, we would change the entire automotive industry,” said Marko Lehtimaki, CEO of Donut Lab. One of the main components of the platform is the donut-shaped motor, which the company says enables better performance than other electric motors in all vehicle categories. In addition, a motor installed directly in the wheel eliminates the need for a drivetrain. The platform speeds up the development cycle of EVs and can reduce the resource requirements for development by up to 95%, compared with the current level, Donut Lab says, so work that used to take several years can now be completed in a matter of months. Click here to access more news articles & deeper technical investigations into e-mobility ▶ https://lnkd.in/exVm22ce #electricvehicles #ev #automotive #emobility #emobility #electrification