E-Mobility Engineering 019 | In conversation: Stephen Lambert l WAE EVR l Battery case materials focus l Quality control insight l Clipper Automotive Clipper Cab digest l Optimising battery chemistries insight l Powertrain testing focus

12 May/June 2023 | E-Mobility Engineering TheGrid Plastics offer key role in designs Worldwide spec formining sector P lastics are now able to replace metal for the construction of EV charging stations (writes Nick Flaherty). SABIC has created a concept demonstrator madewith all-plastic components to showcase the use of high- performance plastic resins and blends in EV chargers, using expertise developed under a project called BlueHero. Compared to metal, plastics offer design freedom by enabling part consolidation and function integration, as well as attractive aesthetics. They also enable production processes to be more streamlined and can reduce costs by using high-speed, high- volume injection moulding and avoiding secondary operations such as painting. Using plastics with the appropriate additives can extend the useful life of a charger through specialised properties such as high impact resistance, weatherability, chemical and UV resistance and flame retardance (FR). A global standard specification for a high-power electric connector for mining vehicles and infrastructure is being developed (writes Nick Flaherty). A mining taskforce is working on and testing the specification with mining firms that include BHP and Rio Tinto, and equipment companies Shell, ABB and GHD. They are defining the requirements, piloting and testing the technical capabilities of the ruggedised charging solutions in mining environments. The resulting specification will be adopted by the CharIN and ICMMgroups. The industry support is critical for trials to prove these technologies are fit for Enclosures and outdoor feeder cabinets of charging units can bemoulded from FR polycarbonate (PC) or blends of PC with polybutylene terephthalate (PBT). SABIC’s Lexan PC resin, for instance, offersmoulded-in colour with high impact strength and FR properties. Inner panels, indoor cabinets and consoles can be produced from an FR blend of PC and acrylonitrile-butadiene- styrene (ABS) to achieve dimensional stability and high impact resistance. A the harsh environmental conditions and complex operations inmining. CharIN has been instrumental in establishing the Combined Charging System international standard for charging passenger EVs and the Megawatt Charging System for heavy transport. However, a new high-power charging solution is needed for the mining industry owing to the large size of the haul trucks. Providing interoperability and standardisation for charging solutions early on could help reduce duplication in charging infrastructure for mines around the world. The ICMM will address technical bottlenecks around the interoperability of battery-electric thinwall FR capability can help reduce weight even further than simply replacing metal, and can free up space for additional components. For structural components such as frames and bumpers, long glass fibre-reinforced polypropylene (PP) compounds such as Stamax resins provide high strength, stiffness and impact resistance for durability, along with the ability to integrate multiple functions in a single part. Optically clear PCs offer benefits for display screens and light guides, that include impact performance and high/ low temperature resistance. They can be hard-coated for abrasion resistance, which is important for touchscreens. Materials with good electrical properties are required for the front door nozzle cover, charging connector, plugs and couplers. An FR PBT or PC/ PBT blend can deliver high electrical breakdown properties, good chemical resistance and low water absorption. charging systems for the roll-out of mine vehicles using electric and hydrogen power. “CharIN members represent all the various industries in the e-mobility ecosystem, from grid to charging point operators to heavy equipment makers to standardisation and testing organisations,” said Claas Bracklo, chairman of CharIN. Anna Wiley, vice-president, planning and technical, at BHP, said, “Developing an interoperability framework for battery-electric equipment is a complex jigsaw that cannot be accomplished without a new level of technical collaboration across the mining and e-mobility industries.” EV CHARGERS CONNECTORS All-plastic EV chargers offer design freedom as well as attractive aesthetics