Focus on...

Battery leak testing

Peter Donaldson delves into the world of battery leak testing. With the exception of old, British motorbike engines – it was said that if they’re not leaking, there’s no oil in them – leaks from anything are usually a sign of a problem. The escape of liquids such as coolant and electrolyte are undesirable, and the emission of gases can be the first warning sign of a thermal runaway.

Deep Insight

HIL Testing

Nick Flaherty traces the line where digital models of components meet simulation to experience a vehicle before it is even built Virtual design methodologies are increasingly being adopted in the development of e-mobility platforms – combining digital models of components with simulation to create a digital twin of an entire vehicle that can be driven before it has even been built.

Digest

Fellten Charge Qube

Peter Donaldson investigates a containerised system that can charge multiple vehicles and doesn’t need a grid connection. Until the electric power grid is able to support fast charging for EVs everywhere, there is likely to always be a market for something like Fellten’s Charge Qube – a containerised system that stores energy in repurposed battery packs and can charge multiple vehicles simultaneously, with or without a connection to the grid.

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Motor testing

Peter Donaldson examines various means of testing electric motors. Although mechanically simple, compared with internal combustion engines, the electric motors forming the heart of the propulsion system of EVs of all kinds must go through intensive testing. This involves the use of many technologies and procedures to probe performance, efficiency, reliability and safety at every stage of manufacture and integration.

In Conversation

In conversation: Tony Fong

Everrati’s head of engineering discusses novel ways of electrifying classic cars with Will Gray Electric vehicle (EV) technology is moving at a rapid pace and much of that is thanks to people like Tony Fong. As head of engineering at luxury electric car company Everrati, he is pioneering cutting-edge innovation in the most unlikely of places – by implanting the latest powertrain components into old classics to create the systems of the future.

Dossier

Doosan Bobcat T7X

Doosan Bobcat is using electrification to not only reduce emissions in construction but also radically change the operation of compact track loaders, reports Will Gray Construction is not the first industry you think of when it comes to sustainability or electrification. Heavy, power-hungry machines do not immediately suggest the ideal platform for battery-powered performance, yet Bobcat has discovered the opposite, with its new T7X compact track loader outperforming its diesel-powered equivalent in almost every area.

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Cybersecurity

Nick Flaherty uncovers new ways to make e-mobility software safer. A competition in Japan has discovered 49 vulnerabilities in automotive software, of which the developers were unaware. In the Pwn2Own Automotive 2025, researchers targeted EV-charging electronic control units (ECUs), where a flaw allowed the manipulation of charging parameters in the powertrain ECU, risking battery thermal runaway.

PS

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.

In Conversation

In conversation: John Stamford

The advanced powertrain chief engineer of Jaguar Land Rover got into EVs before EVs were even a thing. He tells Will Gray how far things have come If you want to understand the evolution of electric vehicles (EVs), there are few better to speak to than Jaguar Land Rover’s advanced powertrain chief engineer, John Stamford.

Dossier

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.

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Battery cell manufacturing

There are three major phases of activity for manufacturing battery cells, as Nick Flaherty reports Moving from small coin cells that prove the performance of a battery chemistry in the laboratory to production is a big step. There are many different ways to construct a cell, and many techniques for both building and characterising the resulting battery.

Show Report

The Battery Show USA show report

A wealth of advanced battery tech for EVs was on show in Detroit, as Peter Donaldson reports. Staged for the first time at Huntington Place, Detroit, The Battery Show and Electric & Hybrid Vehicle Technology Expo, North America showcased a myriad advanced battery technologies. Organiser Informa Markets reports that more than 21,000 professionals from around the world attended and 1250 organisations exhibited, making the 2024 event the largest in its history, which dates back to 2010.

Digest

Dynisma DMG family

Seamless simulation Peter Donaldson checks out simulators designed to give drivers the most realistic response and feel Dynisma’s DMG family of simulators is designed to reduce the time and expense involved in building and testing vehicles by moving as much prototype development as possible into the virtual world. We caught up with the company’s commercial director, […]

Deep Insight

Isolation technologies

Nick Flaherty investigates techniques that enable digital controllers to interface safely with high-voltage systems. As automotive designs move to electrification, high-power electronics have become critical components in new electronic drivetrain and battery systems. Communication and control from low-voltage digital devices requires electrical isolation of the high-voltage elements from the low-voltage side, covered by the extra-low voltage (SELV) regulations.

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Modular batteries

In optimising modular battery technologies, it’s important to harmonise design and control. By Peter Donaldson. Modular battery systems remain an essential component of e-mobility, offering unique advantages that complement recent advancements in cell-to-pack (C-t-P) technologies.

Deep Insight

Cell ageing characteristics

Modelling battery cells at end of life is becoming more popular for key reasons, as Nick Flaherty reports. Accurate prediction of battery lifespan is crucial for e-mobility and involves a variety of test approaches, from thermal measurements to transmission electron microscopes. Assessing how a cell delivers power when required and how it is charged provides insights into its lifetime.

PS

Electrode-to-pack

In the quest for energy density in EV batteries, cell-to-pack (CTP) architectures represent an approach that increases the proportion of active materials by eliminating modules, and their associated structure and interconnections.

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Onboard chargers

Nick Flaherty examines how designers are making OBCs more powerful, faster and lighter. The onboard charger (OBC) market is changing with increasing power levels for faster operation and the need for lighter systems that can be integrated with the other vehicle components.

Digest

ICEBreaker hydrogen HGV

Two companies have teamed up to build a hydrogen-powered HGV using a fuel-cell powerplant, as Peter Donaldson reports. Spearheaded by powertrain energy-management specialist Viritech, Project ICEBreaker has built a hydrogen-powered heavy goods vehicle (HGV) using a fuel-cell power plant, focusing on minimising the weight penalty compared with internal combustion engine (ICE) vehicles.

In Conversation

In conversation: Dr Keon Woo Lee

Peter Donaldson chats to a leading battery expert, who says innovation is all about winning against the things you can trade off. In a rapidly evolving EV landscape, the quest for advanced battery technologies remains at the forefront. Dr Keon Woo Lee leads Henkel’s Fuel the Future Team and Engineering and Advanced Testing...

Dossier

Halevai electric boat

Halevai is on a mission to redefine the recreational marine market, combining an electric powertrain with a trimaran hull, reports Will Gray. It might look like a relatively ordinary recreational day cruiser, but in an industry that is traditionally as slow moving as a heavily loaded tanker, the design of Halevai’s model2050 – which pairs an innovative but highly standard electric powertrain with an ultra-efficient trimaran hull – places it firmly in the ‘ground breaker’ category.

Focus on...

Battery dielectric protection

Peter Donaldson examines multi-function dielectric materials for battery systems. Dielectric protection materials are critical in EV battery systems, where they serve to insulate components from one another, reduce the risks to technicians working on them, and often also contribute to structural strength and thermal management.

Deep Insight

End-of-line battery testing

As battery technology evolves, so the process of testing it all becomes more complex, as Peter Donaldson discovers. End-of-line (EOL) testing for EV battery packs is a critical step in ensuring their performance, safety and longevity, and that of the vehicles they power. As battery technologies evolve, so do the complexities of testing them.

PS

The EV support structure

One of the signs of maturity we should look for in BEV technology is the existence of a robust market in used cars, writes Peter Donaldson. Evidence of this would include a good choice of makes and models with prices that, while strong, are significantly lower than new prices, and they reflect age, mileage, service history and overall condition.

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Gap fillers and TIMs

Peter Donaldson examines the shifting demands on thermal interface materials and suppliers’ innovative responses. Thermal interface materials (TIMs), including gap fillers, are crucial for managing heat in battery packs, sensors and electronics in e-mobility applications. Their developers have to meet changing demands from battery builders and vehicle OEMs as they implement novel architectures moving into cell-to-pack, cell-to-chassis and cell-to-body schemes.

Dossier

Liebherr electric excavator

Rory Jackson finds out how one company met the challenge of electrifying its mining excavators. Despite being known for manufacturing huge, diesel-powered vehicles and industrial equipment, the Liebherr Group has a lengthier history in electrified powertrains than many realise.

Deep Insight

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.

Digest

Bo M electric scooter

A company that aims to make its e-scooter a serious, roadgoing magic carpet explains its vision to Peter Donaldson With a side profile reminiscent of a boomerang and a sleek, unadorned, metallic finish, the ‘M’ stand-up electric scooter from Bo has a distinctive appearance that hints at a fresh approach to an increasingly popular category of minimalist, powered two-wheeler.

In Conversation

In conversation: Neil Yates

Rory Jackson learns the success of a leading skateboard developer. With effectively all automotive OEMs now shifting focus from internal combustion engine (ICE) vehicles to e-mobility, an eye for emerging trends across the industry and its markets has become critically.

Show Report

The Battery Show Europe show report

Peter Donaldson highlights some hot discoveries at Battery Show Europe. In June, Stuttgart Messe played host to the Battery Show Europe, an event that highlighted advanced manufacturing and developments in easing the dismantling of battery packs at the end of their first life, as well as innovative battery architectures, vehicle designs and componentry.

Focus on...

Battery safety

Nick Flaherty reports on the various materials making batteries safer. A new generation of materials is changing the way battery systems for e-mobility are designed. Pack architectures differ depending on the form factor of the cells, with various materials used for cylindrical cells compared with prismatic cells.

Hybrid energy storage systems

Hybrids of all kinds hold out the prospect of the best of both worlds, but the engineering challenge often entails a lot of effort to create something that is greater than the sum of its parts. Hybrid energy storage systems (HESS) that combine batteries and supercapacitor banks are a prime example, writes Peter Donaldson.

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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.

Deep Insight

Harnessing hydrogen

Manufacturers are harnessing the potential of the cheaper, clean energy for shipping and aircraft, reports Nick Flaherty Fuel cells that convert hydrogen into electric power for e-mobility have a chequered past. This has been perceived as high cost, with issues when integrating it into powertrains and supplying hydrogen from pressurised tanks.

Digest

Soteria e-bike project

With lithium-ion batteries among the top causes of fatal fires in New York, Peter Donaldson talks to a company set on making e-bikes less risky It only takes a few minutes on the internet to realise there is a big safety problem with e-bike batteries. Even a basic search for ‘e-bike battery fire statistics’ yields alarming numbers, press reports, government recommendations and official statements, such as the London Fire Brigade’s (LFB) recent declaration that e-bikes and e-scooters are now the city’s fastest growing fire risk.

Deep Insight

Battery production technology

Peter Donaldson looks at the myriad processes enabling more efficient manufacturing of lithium ion batteries Manufacturing lithium-ion batteries for e-mobility applications is a complex, costly and capital-intensive undertaking, involving multiple processes and consuming large amounts of energy and time.

Focus on...

Battery tech for heavy duty applications

With applications ranging from trucks to mining equipment and excavators, vehicle assemblers have a wide pool of requirements, as Nick Flaherty reports Flexibility is a key requirement for heavy-duty electric vehicle (EV) applications. These vehicles are based on existing chassis designed for diesel engines, so battery packs with various chemistries have to be manufactured to fit a wide range of form factors.

Dossier

Fellten Morgan XP-1

The power of three Reinventing its classic 3 Wheeler for the modern world, Morgan has chosen Fellten to electrify the XP-1 prototype, reports Rory Jackson While the Morgan Motor Company has long been known for such unique practices as the handcrafting of its exclusive production runs, iconic car designs that include its classic 3 Wheeler […]

In Conversation

In conversation: Tim Woolmer

The CTO of YASA Motors tells Rory Jackson how his axial-flux ‘pancake’ motors originated from a complex algorithm and a simple question Today, Tim Woolmer is the CTO of axial-flux electric-machine manufacturer (and wholly owned Mercedes-Benz subsidiary) YASA Motors, but his initial entry into the world of e-mobility was something of a happy accident.

Battery repair and recycling

Electric vehicles (EVs) are facing some stiff headwinds in the market. Many are affected by depreciation significantly worse than that of comparable internal combustion engine (ICE) vehicles, the reluctance of dealerships to take them at trade-in time, along with escalating insurance premiums and some insurers refusing to cover them altogether, writes Peter Donaldson.

Focus on...

Thermal runaway prevention

Peter Donaldson speaks to experts who are working on cell design and chemistry to avoid thermal runaway Protection from thermal runaway in an electric vehicle (EV) battery requires a holistic solution that affects every aspect of the pack’s design and operation. The consensus seems to be that protection options are limited to prevention and mitigation rather than stopping a runaway once it has started.

Deep Insight

Battery energy density

Nick Flaherty looks at strategies to get more power out of battery cells, which brings thermal management challenges. There are many ways to boost the energy density of an e-mobility platform’s powertrain. The materials in a battery cell can be improved to produce more energy, from silicon in the anode to new electrolytes. Solid state

Digest

Electrogenic E-type conversion

Peter Donaldson reports on an electric powertrain developer that undertakes bespoke conversions for classic cars. Electrogenic is a leading developer of electric powertrains for niche vehicle manufacturers. It also carries out bespoke conversions of classics, such as the E-type Jaguar, to electric power and produces conversion kits.

Deep Insight

Coil windings

Peter Donaldson takes electric machines apart to examine the inner workings of coil windings. At first glance, electric machines are simple. They have one moving part, the rotor, which either rotates in response to an input of electrical energy or puts out an electric current in response to an input of mechanical energy that rotates it.

Focus on...

Battery sealing

Nick Flaherty assesses the various materials and processes used to seal and protect a battery pack Sealing a battery pack safely is a key requirement for e-mobility systems. While there may be concerns about the ingress of moisture or dirt, there are also issues over venting gasses and preventing electromagnetic interference. As a result...

Dossier

H2D2 snow groomer

A unique project plans to electrify the niche market of snow groomers, reports Rory Jackson More than 300 ski resorts decorate the five mountain ranges of France, and these are home to some vehicles that are quite unlike those found at any other kind of sporting retreat.

In Conversation

In conversation: Dr Richard Ahlfeld, Ph.D.

Monolith’s CEO tells Rory Jackson how AI can help improve and shorten vehicle and powertrain development For much of the 21st century, automotive applications of big data have been limited to some attempts at predictive maintenance in vehicles and powertrains.

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Inverters

Modern inverters are including more intelligent features to work with other vehicle systems, reports Peter Donaldson Inverters do the conceptually straightforward job of converting an electric current from DC into AC form. As such, they create an essential link between the energy storage system and the motor. Modern inverters use

Deep Insight

Power semiconductors

Nick Flaherty discovers how the world of power semiconductor devices is shifting away from silicon Power semiconductors are used across many areas of e-mobility, with different technologies suitable for each part of a vehicle, depending on the voltage and current requirements, while emerging tech is allowing smaller systems to be implemented.

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Polymer considerations for EV

Lightweight with higher temperature resistance, thermoplastics are ideal for e-mobility powertrains, Nick Flaherty reports The push to make e-mobility designs lighter to boost range is driving significant innovation in materials. Thermoplastics are being redesigned to provide various combinations of temperature and flowability for manufacturing and plating capabilities.

PS

Bipolar batteries

When Toyota unveiled plans for its next generation of EV technology in June 2023, the company made it clear that bipolar batteries would play a central role. The company is already using bipolar architecture in the nickel-metal hydride batteries in its Crown

Deep Insight

Potting & encapsulation

Peter Donaldson examines the finer points of potting and encapsulation Many electrical and electronic components last longer, perform better and stand up to the stresses and strains of hard use with fewer complaints if they are potted or encapsulated in a polymer. While the two terms are often used interchangeably,

Digest

BEDEO van conversion

Peter Donaldson discovers how conversion packs are putting electric powertrains inside diesel vans One of the greatest benefits of electrified light vehicles is the elimination of tailpipe emissions and the consequent improvements in air quality in urban areas. Large vans form a key part of the ‘last mile’ logistics that keep cities

Dossier

Frauscher x Porsche 850 Fantom Air

Rory Jackson explains how Porsche has collaborated with boat-maker Frauscher to take its latest generation e-powertrain onto the water Since boating as a mobility form is largely motivated by sport and leisure, the quietness of an electric motor versus an internal combustion engine is prized by many. The easier repair and maintenance of

In Conversation

In conversation: Michael Fischer

Honda R&D Europe’s deputy GM talks with Rory Jackson about changing where EVs stand relative to the environment, the grid and the home. A drive to understand how complex machines work can spur one towards a life of engineering and research across a diverse field of sciences, as Michael Fischer, deputy GM of Honda

Digest

RS Electric Boats Pulse 63

Peter Donaldson explores a new generation rigid hull inflatable boat that obtains benchmark performance from electrical energy. While sailing is emissions free, the IC-engined boats that regularly support sailing events and training operations tarnish that clean image somewhat. This led the principals at RS Sailing, now part of the RS Marine Group, to begin development of an electrical Rigid Hull Inflatable Boat (RHIB) in 2018, incorporating a new company, RS Electric Boats. The resulting Pulse 63 is now operational in its intended role as a sailing coach boat and is also offered as a work boat, a leisure boat and a superyacht tender.

PS

A question of bandgap

As system voltages in EV powertrains increase to enable the use of higher power levels without creating excessive currents and the associated energy losses and heat dissipation problems, so does the importance of wide bandgap semiconductors, writes Peter Donaldson. Ones such as silicon carbide (SiC) and gallium nitride (GaN) in applications such as traction inverters, DC-DC converters and onboard chargers.

Focus on...

Battery inspection

Getting inside a battery to check its integrity or to trace a fault in a non-destructive manner is technologically challenging, as Peter Donaldson explains Mass producing large capacity lithium-ion batteries to meet the anticipated demand for EVs while ensuring that they are as safe, dependable and long-lived as possible is driving the need for faster, more thorough and more reliable inspection systems.

Deep Insight

Immersive cooling

Nick Flaherty explains the advantages of immersion cooling and the various forms that approach can take Immersive cooling can significantly improve the performance of e-mobility powertrain designs, allowing higher charging and discharging rates and extending the life of battery packs by keeping the temperature of battery cells under much tighter control.

Focus on...

Phase change materials

Phase change materials offer intriguing possibilities in the thermal management of EV powertrains as Nick Flaherty explains Phase-change materials (PCMs) are known for their superior latent heat capacity, acting as heat absorbers without notable temperature increases. This property can be used in many different ways throughout the powertrain of e-mobility systems, from enhancing the heat transfer in the power electronics to cooling the entire battery pack

Deep Insight

Battery coatings

Peter Donaldson finds complex challenges within the development of coatings for battery applications Coatings play a crucial role in battery cells, modules and packs. Evolving continuously, they are engineered to enhance performance, safety, reliability and longevity in these complex, high value electrochemical systems. While the

In Conversation

In conversation: Tony Persson

Scania AB’s head of battery production Tony Persson explains to Rory Jackson his company’s key role in the development of electric vehicles for demanding applications The race to electrify road vehicles is bringing with it a race to develop internal competencies in producing key e-mobility technologies, and battery packs frequently

Dossier

H3X

H3X is meeting the challenge of maximising continuous power output against high operating temperatures. Rory Jackson reports Commercial aviation is one of the world’s fastest-growing sources of pollution, responsible for about 2% of global greenhouse gas (GHG) emissions and 2.5% of carbon emissions. These levels are projected to reach...

Deep Insight

Improving power electronics

Nick Flaherty reports on how semiconductor r&d is leading to more efficient and powerful electronic switching solutions for e-mobility Power devices for e-mobility come in a range of technologies to boost performance and efficiency. Insulated gate bipolar transistors (IGBTs) made from silicon have been the original power switch for decades; they are robust and low cost but can only switch at frequencies of around...

PS

Extinguishing lithium battery fires

Our battery show report in this issue contains stories on various materials engineered to prevent a thermal runaway in a cell in a lithium-ion pack from spreading and cause a major fire (writes Peter Donaldson). Prevention is better than cure because, rare though they are, thermal runaways in EV lithium-ion batteries contain all four elements of the ‘fire tetrahedron’ – heat, oxygen, fuel and a chemical reaction – making them notoriously hard to extinguish. Putting them out is far from impossible, however.

Focus on...

Motor control

Nick Flaherty explains the various ways to create the perfect sine wave to maximise the efficiency of electric motor control Improving the efficiency of e-mobility motor control is a key focus for developers. Design technologies to squeeze the last microamp out of the battery can boost the range of EVs significantly, while improving the efficiency of the motor control can reduce losses, cutting the amount of thermal management needed and so reducing the complexity and weight of a motor.

Show Report

The Battery Show report

Peter Donaldson gives his round-up of the products on display at this show, where the focus was on tackling thermal issues This year’s Battery Show North America and Electric & Hybrid Vehicle Technology Expo, held in Novi in Michigan, had if anything an even greater emphasis on battery safety than usual, with many innovations aimed at stopping a thermal runaway in its tracks, as well as on thermal management.

In Conversation

Dr Tilo Schweers

Smart Europe’s vice-president of r&d shares some of his insights into developing the company’s distinctive battery EVs. By Rory Jackson While automotive OEMs might now agree that electric powertrains are effectively the future of all mobility, it should be remembered that only 20 years ago, many of them saw electrifying vehicles as a peculiarity at best, and a waste of resources at worst.

Focus on...

Axial flux motors

Peter Donaldson canvasses expert opinions on the decisions to be made on whether to choose an axial flux motor for a given application Axial flux (AF) motors are attracting a great deal of attention and engineering effort in the e-mobility arena, and for good reasons. Different motor topologies – such as radial and axial flux – are...

Dossier

Xerotech battery system

Unlike road EVs, off-highway vehicles need different battery solutions but in only small batches. Rory Jackson looks at how this company addresses that For on-highway vehicles, electrification is now seen as the way to go, but the future for electrified off-highway ones such as construction dozers, mining trucks and so on is less clear.

Digest

Submarine lessons for battery EV fire safety

Fires aboard the car carriers Felicity Ace and Freemantle Highway, which were transporting battery EVs, should concentrate minds in governments, regulators and industry – regardless of whether the fires were caused or sustained by thermal runaways in the batteries (writes Peter Donaldson).

Deep Insight

Electric motors for aircraft

Developments in motors for e-aircraft are becoming intertwined with issues of energy storage and certification. Nick Flaherty reports There are many different designs for motors being developed for a variety of electric aircraft platforms, from vertical take-off air taxis to 100-seaters with a flying time of an hour or so for regional flights.

In Conversation

Marko Lehtimaki

The CTO at Verge Motorcycles tells Rory Jackson why rider comfort is more important than aesthetics in its hubless direct-drive e-bike The riding experience is important in consumer EVs, especially electric motorbikes. Persuading veteran riders to go electric is far more than a matter of mitigating range anxiety, as the bikes are ridden for...

Focus on...

Busbars and interconnects

Large EV battery packs can contain thousands of cells that have to be connected to form modules and packs, then connected via busbars to other driveline components such as inverters and DC-DC converters to make robust and reliable connections quickly and efficiently in confined spaces while keeping costs down. That has made...

Focus on...

Battery surface analysis

Nick Flaherty explains how techniques for analysing the surface of battery materials are leading to better cell designs Materials analysis is essential in developing new battery components and ensuring they meet high standards of quality. Thermal analysis plays an important part in raw material characterisation, especially for thermal runway issues.

Digest

Dieseko Woltman pile-driller/driver

Peter Donaldson reports on how this zero-emissions version of a diesel piling rig has been designed and developed Drilling piles into the ground has been a crucial task in building for thousands of years. Whether they’re made from timber, reinforced concrete, steel or aluminium – and whether in column or sheet form – they help to stabilise the ground and make it more able to support heavy structures.

Deep Insight

Battery welding

Welding experts give Peter Donaldson their views on how the technology is keeping abreast of developments in the EV batteries industry Welding is a vitally important family of joining techniques for EV battery systems. A large battery might need thousands of individual connections, joining the positive and negative terminals of cells...

Dossier

Nyobolt EV

Despite the pace at which sales of electric passenger vehicles are growing, and the promise they hold for lowering worldwide carbon emissions, there is a major conflict between the way EV designs are evolving and how that threatens to create serious problems for the sustainability of automotive supply chains.

PS

Squaring the circular economy

Anyone who has been to a vehicle scrapyard will know that recovery of components and reuse of materials has long been part of the automotive industry. However, today the focus on the circular economy is sharpening and the cradle-to-grave concept of a product’s

In Conversation

Ian Foley

Equipmake’s CEO explains the technologies that underpin the company’s evolution into scale production of e-mobility motors. Rory Jackson reports While specialising in a market niche is useful for some e-mobility component manufacturers, others can find that it pays to diversify. Equipmake falls squarely into the latter category, having...

Digest

Rolls-Royce Spirit of Innovation

Peter Donaldson examines the design and technology that went into making this electric aircraft a record-breaker. Electric aviation is roughly where piston-powered flight was in the 1920s and ’30s, in that record-breaking really matters to the credibility of the idea almost as much as to the impetus it gives to the development of electric aircraft technology.

Deep Insight

Lithium iron phosphate batteries

Developments in LFP technology are making it a serious rival to lithium-ion for e-mobility, as Nick Flaherty explains Lithium-ion batteries have some disadvantages for e-mobility that cannot be ignored, such as lower safety and higher cost than other chemistries. At the same time, improvements in battery pack technology in recent...

Dossier

magniX magni350, 650 and magniDrive 100

Rory Jackson looks at how these electric powertrains and their inverter have been designed for crewed aircraft integrators In every part of aerospace engineering, a race is on to break new ground and claim headline-grabbing milestones in sustainable aviation. While it might seem to some that commercial airliners are moving at a sluggish pace...

Focus on...

Fuses and circuit protection

Nick Flaherty reports on how new circuit protection technologies are meeting the challenges posed by increasingly powerful EVs The EV market these days is seeing demand and development towards decreasing charging times, increased range requirements and a wider variety of vehicle models. All of this heightens...

Focus on...

Adhesives

Increasingly important in multiple applications in vehicles of all kinds, adhesives are central to the assembly of batteries, power electronics and motors used in EVs. Current development efforts are focused in areas such as ease of use in volume manufacturing as the EV industry gears up for mass...

Show Report

Battery Show Europe 2023

Held at the Stuttgart Messe exhibition centre from 23 to 25 May, the Battery Show Europe 2023 was a lively and well-attended event that showcased advances in core battery and EV powertrain technology, materials, manufacturing and quality control processes. It also revealed a growing emphasis on repair, reuse, recycling and broader circular economy goals.

Deep Insight

Ammonia as an EV fuel

For all practical purposes, there is more hydrogen in ammonia (NH3) than in pure hydrogen, because hydrogen is a diffuse gas at ambient temperatures and pressures (writes Peter Donaldson).

Deep Insight

Quality control

E-Mobility Engineering talks to quality control technology suppliers about how they are adapting to the transition to EVs. In a recent study of new-car quality, consumer intelligence company JD Power found that owners of battery EVs and hybrids report more problems than those of IC-engined...

Digest

Clipper Automotive Clipper Cab

This e-taxi, converted from the iconic London black cab, is set for real-world trials. Peter Donaldson explains how it’s being developed The urban jungle is a natural environment for battery EVs, as they can take advantage of its stop-start traffic to recover energy through regenerative braking...

Deep Insight

Optimising battery materials

As battery technology moves towards solid-state cells, Nick Flaherty reports on the latest research into improving their performance There are many materials involved in the optimisation of battery cells beyond the anode, cathode and electrolyte...

Focus on...

Battery case materials

The range of materials for developing EV battery cases is growing, and are addressing issues of weight, assembly and even condensation. Glass fibre and composites are opening up design options from modular systems to complete cases, while other materials are helping to improve the properties of the cases, from thermal and electrical

Focus on...

Powertrain testing

The growing shift towards electric and other forms of powertrains is being mirrored by changes in the services from test providers. The state of the market for EV powertrain testing could be seen as buoyant at the moment, as the automotive industry transitions from IC...

Dossier

WAE EVR

Developing a new EV on a pre-existing skateboard-type platform offers benefits in terms of the associated times and costs of development cycles. As previously discussed in this publication, altering the wheelbase of a typical car or truck design by 12-15 cm can entail making so many modifications to the transmission...

In Conversation

In conversation: Stephen Lambert

We chat to McLaren Applied’s head of electrification about how the company’s race-bred technology will filter through to e-mobility...

PS

Better eVTOL landings

Battery-powered manned eVTOL aircraft intended to operate to and from urban vertiports have a sharply limited energy budget, so designing energy-efficient flight profiles for them is obviously important – and if those profiles can also improve passenger comfort and safety at the same time, so much the better

Digest

Eive electric 2CV

French connection This electric version of the classic Citroen van was developed in the UK using an e-drive from a company in France. Peter Donaldson reports Electric conversions of classic cars such as original Minis and early Porsche 911s are now well-established, but the Citroen 2CV van created by The 2CV Shop in the UK […]

Deep Insight

Reduced rare earth and magnet-free motors

The race is on to find ways of reducing the industry’s reliance on EV motor magnets made from rare earths. Peter Donaldson looks at the latest advances Rare earth (RE) magnets are essential components of the most efficient torque and power-dense motors used in EVs. However, factors including price, sustainability and

Focus on...

Automotive Biometrics

Electric vehicles are at the nexus of several ongoing technological and socio-economic transformations. The first includes electrification itself, along with the rise of software-defined vehicles and the application of

Deep Insight

Anode materials

Anode materials suppliers are pouring resources into improving the performance of EV cells. Carbon, in the form of graphite, is the mainstay of the current generation of lithium-ion batteries for e-mobility.

Focus on...

Flexible battery management systems

BMS developers are offering products that are compatible with the growing range of OEM vehicle models. The trend for battery management systems

In Conversation

Asher Bennett

The CEO of Tevva Trucks explains his thinking behind offering goods vehicles with a dual energy system. By Rory Jackson One of the most prominent differences between Tevva Motors, based in

Dossier

Cake Kalk OR

Rory Jackson charts the development of this e-bike, whose entire manufacturing process is geared towards producing zero emissions Supporters of e-mobility as a means of reducing carbon emissions

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Thermal management

Peter Donaldson talks to 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

PS

Individual wheel control

It’s worth taking 9 minutes and 36 seconds out of your day to watch professional rally driver Ken Block’s Electrikhana on YouTube (writes Peter Donaldson). I don’t know whether he is a mathematician, but Block is

In Conversation

In conversation: Matt Faulks

Viritech’s CTO tells Rory Jackson how fuel cell developments for its Apricale hypercar will feed into its upcoming heavy goods vehicles Anyone who works in electrified and low-carbon automotive

Show Report

Battery Show North America 2022

Peter Donaldson provides some highlights of this key event, focusing on new products and technologies that offer solutions to pressing challenges Held in Novi, Michigan, in mid-September

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Battery testing

Nick Flaherty explains the various non-invasive methods of analysing the workings of battery cells and their materials Testing battery cells, modules and packs presents a series of challenges. First of these

Deep Insight

Cathode materials

Researchers have been announcing advances in lithium-ion cathode materials and their manufacture, as Nick Flaherty reports There are three main types lithium-ion batteries for e-mobility, all with

Digest

Ariel Hipercar

There’s more to this e-sportscar than its blistering acceleration, writes Peter Donaldson, it is also designed to advance EV technology “High performance carbon reduction” is a statement of intent for niche

Dossier

ECE electric Doosan DX165W and DX300LC

Rory Jackson provides an in-depth report on how these heavy-duty excavators were converted to electric operation The construction industry is a major

Deep Insight

Torque sensing

Ryan Maughan explains the pros and cons of the various ways to measure motor torque As the market for electrified vehicle powertrains develops, so the quest to deliver improved efficiency and

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User interfaces

Ryan Maughan explains the pros and cons of the various ways to measure motor torque As the market for electrified vehicle powertrains develops, so the quest to deliver improved efficiency and

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Automated battery manufacturing

Cutting-edge research and prototype factories are helping to advance the automation of EV component manufacturing, writes Nick Flaherty Some car makers have had fully

In Conversation

Thomas de Lange

Dymag’s CEO tells Rory Jackson about the company’s composite EV wheel technology and its advantages over traditional counterparts As many readers know, competitive engineering of e-mobility systems takes

Deep Insight

Sodium Batteries

Research into sodium-ion batteries (NIBs) began in the 1970s and ’80s but was overtaken by lithium-ion battery (LIB) research in the 1990s. However, NIBs have recently re-emerged as a potential sustainable and less

Dossier

Aurora Powertrains eSled

Increasing interest in preserving the world’s Arctic regions has generated strong demand among tour companies and eco-tourists for zero-emissions snow-going vehicles. An electric snowmobile would be

Show Report

Battery Show Europe 2022

Advances in coating and materials were some of the key takeaways from one of Europe’s largest battery trade fairs, reports Peter Donaldson Held in Stuttgart as June became July, the Battery Show and

PS

The power of decay

Launched on September 5, 1977, NASA’s space probe Voyager 1 is now the most distant human-made object in existence (writes Peter Donaldson). At the time of writing, the spacecraft had made it more than

Digest

Standard of driving

Rob Coppinger reports on Alpha Motor Corporation’s digital route to creating a more efficient range of EVs for the global market Alpha Motor Corporation’s latest vehicle, the Saga sedan, is building on the technical

In Conversation

Teams builder

Dana Incorporated’s global VP of light vehicle electrification explains how he merges the company’s engineers’ skills into effective units. Rory Jackson reports Over the past 5 years, US auto parts maker

Deep Insight

Challenge of batteries for heavy-duty EVs

High-voltage batteries are indispensable for the electrification and decarbonisation of vehicles worldwide, but the specific energy and energy density

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Hall effect sensors

High-voltage batteries are indispensable for the electrification and decarbonisation of vehicles worldwide, but the specific energy and energy density

Deep Insight

Self-developments

Nick Flaherty explains how higher charging requirements are leading to different approaches to automating the process Developers of charging systems are looking to address key challenges for fast

Dossier

Six-pack muscle

Peter Donaldson traces the development of this go-anywhere EV created to carry multi-tonne payloads EMotive’s 12 t Scarab 6×6 electric off-road truck is designed to appeal to a range of industries including

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HVAC Systems

Peter Donaldson canvasses industry experts about the EV-specific issues surrounding HVAC systems While most drivers of IC-engined vehicles are vaguely aware that running the air conditioning increases fuel

Deep Insight

Supercapacitor applications

Supercapacitors and batteries make an ideal team, reports Peter Donaldson, who reports on how they are used in EVs Although batteries and supercapacitors both store electrical energy, they do so in very different

Dossier

InoBat Auto

Rapid development of innovative new cell technologies and a focus on tailoring chemistries to maximise the effectiveness of individual applications are at the heart of InoBat Auto’s approach to EV battery development.

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Battery Monitoring

Sophisticated technologies are becoming necessary for faster monitoring of cell behaviour. Nick Flaherty reports Monitoring the performance of battery cells in a pack is pushing the limits of technology in many ways.

PS

Battery swapping, and the alternatives

Whether you drive a single battery EV or operate a fleet of them, ensuring there is enough energy in the battery to complete the job in hand is bound to be a major

Digest

Green-G ecarry

Rory Jackson investigates this custom-built EV for collecting refuse in the narrow streets of older town and cities The dangers of excess CO2, NOX and other greenhouse gases from refuse and freight trucks in

Deep Insight

Lithium-sulphur batteries

Lithium-sulphur batteries suffer from short lifetimes from the polysulphide shuttle effect. Nick Flaherty reports on attempts to reduce this The most significant advantage that lithium-sulphur (LiS)

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Cell-to-pack batteries

Most EV battery packs are built from groups of cells housed in modules interconnected within a case that provides structural support, thermal management, environmental protection and connectivity with the rest

In Conversation

Brandon Fisher

Eaton’s head of HV safety systems talks to Rory Jackson about his career so far and the company’s work in the EV sector As electric powertrains move from 400 V architectures up to 800

PS

Electric trams and trolley buses

In the West we are still addicted to the car as the ultimate embodiment of personal mobility (writes Peter Donaldson). However, there is growing awareness of the total carbon footprint of transport, and even the most

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Solar power

Solar cell technology is near the point of becoming mainstream in EVs, but some obstacles to their use still need to be overcome. Peter Donaldson reports According to the NASA Earth

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Solid-state batteries

As batteries that use solid instead of liquid electrolytes begin to appear, Nick Flaherty cautions that challenges remain in bringing them to market Solid-state batteries (SSBs) are seen in some

Digest

Ricardo Tees Valley hydrogen bus

With this this hydrogen-electric bus set for its first demonstration run, Rory Jackson talks to its developers about the thinking that went into it When discussing clean energy technologies, debates can arise

Show Report

Battery Show Europe 2021

Peter Donaldson reports with highlights of this show, at which ways of containing thermal runaway were at the fore If there was one theme that shone out from conversations at the Battery Show

Dossier

Lightyear One

Rory Jackson explains how this aerodynamic five-seater has been designed for daily trips purely on solar power While EV technology has come a long way over the past decade, the main concerns being raised by engineers

In Conversation

Allan Paterson

Britishvolt’s head of r&d tells Rory Jackson how his experience in battery cell technology has led to him being involved in setting up the UK’s first gigafactory In high-tech industries such as the EV

Deep Insight

Switching

Nick Flaherty examines how new technologies are boosting the performance of inverters and onboard chargers Switching is at the heart of the electrical systems for e-mobility platforms. The performance of the switching devices – the transistors – determines the

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48 V systems

Moving to power distribution networks running on 48 V looks set to confer a range of benefits to battery-electric vehicles. Nick Flaherty reports Technology based on 48 V has been adopted for

Dossier

Sigma Powertrain EMAX transmission

Peter Donaldson reports on how lamination technology has evolved in recent times to meet changing demands from the EV industry Whether or not governments

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Motor laminations

Peter Donaldson reports on how lamination technology has evolved in recent times to meet changing demands from the EV industry Whether or not governments eventually ban the manufacture of

In Conversation

David Hudson

Talking the talk The head of EV strategy at ePropelled tells Rory Jackson how he came into the role and shares details of the company’s dynamic torque switching technology Predicting growth or decline across different areas of the e-mobility world is challenging at the best of times. These days it is even more complex, with […]

Digest

Everrati Porsche 911

The consumer EVs sector is welcoming a constant tide of all-new electric cars, often designed from blank sheets. However, this approach neglects not only the many existing IC-engined cars on the road now, but the countless classic car designs that remain some of the automotive world’s proudest and most cherished examples.

Deep Insight

EV dynamics

How a car moves in response to the forces acting on it is a fundamental determinant of safety, comfort, energy efficiency and driver engagement, and electrification of the powertrain profoundly affects that dynamic behaviour. This influence results from differences in the vehicle’s overall mass and its distribution, when compared with IC-engined vehicles, along with the speed and precision of response inherent in electrical machines.

Focus on...

Battery recycling

Recycling batteries from e-mobility platforms, particularly lithium-ion and lithium iron phosphate (LFP) cells, is an area of increasing focus for the e-mobility industry.

PS

Towards a 1000-mile range

One thousand miles is a nice, round number, and as a range for a battery EV it is a marketing department’s dream. However, there is real value in such a long range if it can be achieved by a production roadcar in representative trim rather than niche vehicles and technology demonstrators.

Deep Insight

E-motor materials

The need for low weight and high performance in e-mobility motors is driving a demand for specialist metal alloys and insulating materials that are also thermally conductive. There is a strong focus as well on how they are sourced, particularly with regard to heavy rare earth (HRE) elements. Dysprosium and neodymium for example

In Conversation

Robert Hoevers

Although DC fast charging and hydrogen refuelling are gaining in popularity for quickly replenishing EV energy stores, considerable infrastructural investment is needed if sufficient charging stations and hydrogen supply points are to be made available for consumers and commercial fleets

Deep Insight

ZeroAvia hydrogen-electric aircraft

As detailed in the first issue of this publication (Winter 2018) through our discussions with Pipistrel about its Alpha Electro aircraft, it is just as feasible to develop (and certify) a two-to-four seater plane to run on battery power as it is with a roadcar. While serious optimisation of the battery and overall system weight must be undertaken to make small battery-electric planes flightworthy, it is empirically achievable.

Focus on...

Sealing

Seals and sealants perform a host of unsung but vital functions. Peter Donaldson explains the different types, their uses and the materials they are made from

Dossier

Candela C-7 speedboat

Hydrofoiling gives this serial production boat high speed and long endurance. Rory Jackson examines the engineering decisions behind its design. When it comes to designing new kinds of boat hulls that will get as much power and endurance as possible out of battery-electric powertrains, one of the smartest things a maritime architect can do is simply lift the boat out of the water

PS

Lofstom Loop

Several electric revolutions have shaped society down the years, from the construction of national grid systems and electric train, trams and trolley buses to the ongoing hybrid and BEV revolution (writes Peter Donaldson). Even beyond Earth, electric propulsion is a reality for many satellites and planetary probes, although their extremely efficient ion thrusters and so on are all low-power devices incapable of developing the thrust needed...

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Battery Safety

The EV battery industry offers a variety of ways to minimise the hazards they can pose, as Peter Donaldson explains. Proximity to large amounts of energy has always presented hazards, but people have mostly learned to live with them and enjoy its benefits....

Deep Insight

Wireless Charging

With agreement on an SAE standard for wireless charging systems set to herald their wider roll-out, Nick Flaherty reports on developments in the technology. The technology for wireless charging of e-mobility systems has reached a critical point. With the SAE J2954 standard now agreed for consumer EVs...

Digest

Riversimple Rasa

Rather than go all-out on the technology, this EV has been conceived with reusable components – and the circular economy – in mind. Rory Jackson reports. End-to-end sustainability is a troublesome target for EV engineers to track. Reducing vehicle emissions at the point of use is easy enough, but reducing the emissions...

Deep Insight

NVH

Peter Donaldson reports on the tools and methods for optimising the acoustic environment in EVs. Of all the disciplines required for developing cars, psychoacoustics isn’t one that readily springs to mind. However, this science of the relationships between aural stimuli and the responses they produce in people informs the branch...

Deep Insight

Skateboard platforms

Against the backdrop of a boom in skateboard platforms for EV designs, Nick Flaherty looks at the approaches taken by some of their suppliers. Changing the wheelbase of a traditional car or truck design by 6 or 7 in creates a ripple effect whereby half the transmission shaft has to be redesigned, changing the centre of gravity and the requirements for the suspension. That means a whole new vehicle design is needed...

In Conversation

Andrew Cross

Integral Powertrain’s CTO tells Rory Jackson how he has come to lead the company’s development of high performance consumer EV drives. One of Andrew Cross’ most prominent early memories is the engineering company his father owned and ran, designing and manufacturing polymer parts, and developing much of his own production systems and tooling...

Dossier

Irizar Group ie truck

Rory Jackson investigates the development of this electric/hybrid refuse truck, which is already operating in various European countries. Developing heavy EVs for urban applications, where regulations on emissions and noise are the strictest of any operating environment, requires a wealth of research...

PS

Tesla Octovalve analysis

It’s not often that we get the opportunity to dig into the details of an important EV subsystem from the point of view of an independent engineering team, but that is what Cory Steuben of Munro & Associates provided at the recent Battery Show and EV Tech online event (writes Peter Donaldson). The subsystem was the Tesla Model Y’s heat pump, in particular...

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Battery cooling

As liquid-based cooling for EV batteries becomes the technology of choice, Peter Donaldson explains the system options now available. Although there are other options for cooling EV batteries than using a liquid, it is rapidly taking over from forced-air cooling, as energy and power densities increase. It is emerging as the dominant technology...

Deep Insight

Vehicle-to-grid charging

Although bidirectional charging for EVs remains a niche technology, writes Nick Flaherty, progress on its uptake is being made. Vehicle-to-grid (V2G) charging is an appealing technology, as it enables EV batteries to be used as part of the electricity grid to even out demand. For example, electric car owners could charge their...

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Condition monitoring

Peter Donaldson examines the factors involved in keeping tabs on the health and performance of key EV components. While an EV’s most costly component is its battery, there are also many other subsystems – inverters, generators and so on – whose condition is critical to safety and efficiency. Machinery health and usage monitoring is well-established...

Digest

VIA Motors CHEMA skateboard

This hardware system puts modularity at the heart of commercial EV designs. Rory Jackson describes how it was designed and developed. For more than 10 years, Utah based VIA Motors has strived to develop technologies and system architectures for EVs to bring to fruition its vision for the next generation...

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Power electronics

Nick Flaherty explains the three types of switching technologies for inverters and how to match them to a given inverter design. Power electronics is of course a key technology for e-mobility systems, and the development of their components is a vital part of the evolution...

In Conversation

Dr Pat Anderson

VerdeGo Aero’s CTO talks to Rory Jackson about how his academic work feeds into the company’s commercial development of aviation technology. Aviation has been a constant presence in Dr Pat Anderson’s life. One of his earliest memories is being visited at the age of five by his uncle...

Dossier

Energica Eva Ribelle

Rory Jackson explores how this e-bike combines the efficiency for urban commuting with the performance for recreational use. Since its founding in 2014, the Energica Motor Company has sought to combine cuttingedge electrical engineering with designs that capture the ergonomics and aesthetics needed to thrive in the world...

PS

Battery reuse and recycling

As awareness grows of the environmental problems associated with several types of lithium mining and extraction, it is becoming obvious that the eco-friendly shine on EVs could soon become tarnished unless those processes are cleaned up and a circular economy for lithium-ion batteries and the materials in them can be established (writes Peter Donaldson). A circular economy means reusing...

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DC-DC converters

Peter Donaldson investigates the technology that underpins these essential voltage switching devices. In modern pure electric and hybrid vehicles, battery voltages of 300- 400 V is becoming common, 600 V is gaining ground and 800 V systems are starting to emerge, all to help produce more power yet keep...

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Thermal Management 2020

Peter Donaldson reports on the methods and materials for keeping EV batteries and other components in their optimum temperature range. Thermal management is the art and science of moving heat energy around to keep various components of a vehicle – and its occupants – at safe, efficient and comfortable working...

Deep Insight

Battery Testing

Battery test systems are proving key to speeding up the development times for new batteries, as Nick Flaherty explains. At the heart of testing battery cells, modules and packs are the levels of voltage and current. Temperature and pressure are increasingly important conditions ...

Digest

Workhorse Group C-Series

Rory Jackson details the development of these electric delivery vans, which have been designed and built from the ground up. The Workhorse Group designs and builds battery-electric medium-duty trucks, and earlier this year it started production of its C-Series vans...

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Battery materials

Nick Flaherty reports on how recent advances in materials are leading to EV batteries with ever-growing energy densities. Battery systems for e-mobility platforms are based largely around lithium chemistry. Liquid lithium salts with graphite anodes and composite metal cathodes are the dominant combination for battery cells...

In Conversation

Thierry Caussat

The next generation - VIA Motors' CTO takes Rory Jackson through the company's series of advances towards fully electric mobility solutions. Throughout his childhood in Toulouse, France, Thierry Caussat could often hear the sound of Airbus’ Concorde airliners screaming...

Dossier

Liebherr ETM Series

Developing these all-electric cement mixer trucks has meant blending the bespoke with the off­-the-shelf. Rory Jackson reports. The conventional cement truck is a diesel-powered vehicle that spends much of each working day at a standstill. However, whether it is having concrete...

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ECUs

Peter Donaldson reports on the latest development trends in engine control units, and the factors driving them. While the entire powertrain of an EV is much simpler than that of a typical modern car with an internal combustion engine, the number and sophistication of the electronic control units (ECUs) distributed around road-going EVs in particular continues to grow as...

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Measuring methods and equipment

New component measurement technologies are complementing traditional methods, and are now being integrated into EV production lines, writes Peter Donaldson. Metrology methods and equipment used in the manufacture of EVs are no different in principle from those applied to IC- engined ones, but their powertrains are built using a different set of...

Deep Insight

EMI

Nick Flaherty explains the different ways of protecting against EMI in EV platforms, and why it needs to be considered from the earliest stages of system design. Essentially there are only three ways to handle electromagnetic interference (EMI) – don’t produce it, filter it out or shield from it. These options lead to a wide range of design trade-offs in e-mobility designs, from the power systems through the...

Digest

vRbikes vR3

Rory Jackson looks at how this three-wheeler has been designed to carry as much cargo as possible in the smallest footprint possible. Given that an electric powertrain brings with it lower maintenance times and costs compared with ICE powertrains, so more and more EV developers are looking to ‘right-size’ their vehicles into smaller and more compact architectures, for ease of use and...

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Fuel cells

Nick Flaherty explains the issues at play when designing and building a fuel cell. Sometimes it seems that the specification and design of a fuel cell is more of an art than a matter of engineering. While the basics of the cells are clear, most often based around a stack of proton exchange membrane (PEM) cells...

In Conversation

Henrik Fisker

Fisker Inc's founder tells Stewart Mitchell why the company's first car will be a mass-market, all-electric SUV. For the past few decades, automotive designer and entrepreneur Henrik Fisker has been working on high-performance luxury sportscars and unique coach-builds...

Dossier

Elaphe L1500 in-wheel motor

The L1500 has been designed to enable it to be used in a wide range of OEM EVs and HEVs. Rory Jackson reports on how it was developed. Slovenian company Elaphe is known in the e-mobility industry for its in-wheel propulsion technology, which is used in a range of automotive applications around the...

Deep Insight

Power and torque density

How do you choose the most suitable type of motor for a given application? Peter Donaldson gets some expert input. One of the many challenges facing the developers of the BB Green ferry project was finding an electric propulsion motor of sufficient power, power-to-weight ratio, compactness and...

Show Report

Electric & Hybrid Vehicle Technology Expo Europe 2018

Lawrence Butcher reports on some of the latest products that caught his eye at this major e-mobility show. May 2018 saw this annual expo take place in Hanover, Germany, where it also incorporated The Battery Show. Concurrently, the conference element of the show saw a...

Focus on...

Connectors

Choosing the most suitable type of connector for an electric vehicle subsystem is governed by a range of factors, as Rory Jackson explains. Connectors are such vital components in vehicles that they make any explanation of their role redundant. What can be underestimated though are...

PS

Superconducting aircraft motors

Power density and power-toweight ratio have always been very near the top of the list of essential attributes for aircraft propulsion systems, particularly in those elements that work at the sharp end of converting stored chemical energy into thrust (writes Peter Donaldson). Rockets aside, the gas turbine engine has yet to be beaten in this respect. In the electrified...

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eAxles

Peter Donaldson canvasses some Tier 1 suppliers’ views on contemporary eAxle technology and the likely future trends in their design. Integrating a motor, gearing and power electronics into a compact, modular package that sits between a vehicle’s driven wheels creates a system that has come to be known as an eAxle. It is an increasingly attractive option for...

Show Report

Battery Show North America 2019 Part 2

Rory Jackson follows up his first report from this show with further highlights of the products that were on display. There were so many new innovations at The Battery Show – its largest to date – that we didn’t have room in our previous issue (Winter 2019) to highlight all the ones we...

Deep Insight

Welding

Nick Flaherty explains the pros and cons of the various welding techniques for connecting cells to form battery packs. A battery pack in an EV consists of a large number of individual battery cells that are held together mechanically and connected electrically. Making those mechanical and electrical connections poses several challenges, including the joining of multiple thin...

In Operation

Lightning Systems LCF truck

Rory Jackson reports on how this electrified version of a mainstream truck is operated and maintained. Lightning Systems carries out full all-electric powertrain integrations on commercial road vehicles such as cargo trucks, buses and passenger shuttles. Founded in 2008 with a focus on hydraulic hybrid propulsion technology...

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Magnetics

Making electric motors more efficient means looking beyond the magnetic materials and switching techniques, as Nick Flaherty explains. The development of the first rare earth magnets in the 1960s by scientists at the US Air Force Materials Laboratory introduced a key new capability for e-mobility. Combining yttrium and cobalt in an...

Dossier

BB Green ferry

Rory Jackson looks at the development of this battery-powered ferry, which is aimed at shuttling workers to and from work. As more and more people find work in the major urban centres of the world, traffic congestion continues to worsen. While road networks struggle to cope with an ever-growing number of commuters, levels of driver stress and greenhouse gas...

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Lightweight materials

Dan Fleetcroft explains how selecting the right materials can minimise an EV’s weight to maximise its endurance. Consumer interest, combined with the world’s growing concern about the environment, is accelerating the development of electric and hybrid vehicles, driving electrification into multiple industries. Government targets on emissions are having as impact on...

PS

Augmented Sound

For petrolheads, a car is far more exciting and generally satisfying if it makes a good noise (writes Peter Donaldson). These issues have led the industry, perhaps inevitably, into the controversial area of artificial sound, partly to increase driver appeal and partly to meet regulations that demand augmented exterior sound from EVs to improve safety in...

Show Report

Battery Show North America 2019

The latest battery cooling, management, monitoring and other related technologies were exhibited at this show. Rory Jackson has some highlights. Every year, the Suburban Collection Showplace in Novi, Michigan, plays host to The Battery Show North America (co-located with Electric & Hybrid Tech Expo North America). With more than...

Deep Insight

Fast Chargers

Planned roll-outs of fast chargers have highlighted the main issues and challenges for their design and development. Nick Flaherty reports. Over the past five years, the number of fast chargers available worldwide has increased tenfold, and over the next five the aim is to have one fast charging station available for every 100 electric...

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Onboard Chargers

EV users who need to prioritise safety and running costs should look to onboard chargers. Rory Jackson examines the engineering and technology inside them. The viability of electric and plug-in hybrid vehicles depends on how quickly, efficiently and safely their battery packs can be recharged. At the moment, the charging times are...

In Operation

Lion8 refuse truck

Rory Jackson details the development of this combined all-electric truck and refuse collection system. When the owners of the Lion Electric Company first set their eyes on engineering specialised commercial vehicles for niche users who have distinct operational and cost requirements, they spent an initial five years on planning and r&d for their...

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Radial flux motors

The latest trend in radial flux motor design is to boost power density while reducing cost. Nick Flaherty explains how it’s being done. The radial flux motor is the workhorse of e-mobility. The basic structure of a static rotor (stator) driving a moving rotor in a radial magnetic field is used in different form factors and power ranges for all kinds of...

Dossier

Performance Projects / Dynium electric tractor

Peter Donaldson relates the development of this tractor’s powertrain, which is designed to operate in confined spaces. When Dynium Robot decided to rethink the tractor to work in the confined spaces of orchards and polytunnels, the off-road robotics specialist turned to racecar engineering company Performance Projects to design the vehicle from...

PS

Race for battery breakthroughs

While lithium-ion battery chemistries continue to improve rapidly, a number of rival technologies and their developers are tantalising the EV industry with promises of much higher energy densities, but always with a caveat or two in other critical areas (writes Peter Donaldson). Some of these technologies represent improved...

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Inverters

Nick Flaherty explains the issues involved in developing inverters for different types of vehicle. The design of an inverter for an electric vehicle depends very much on the application. Full electric, hybrid, commercial bus and...

Digest

Tropos Motors ABLE-XR

Matching the size of vehicle to the size of job was the inspiration behind developing this utility vehicle. Rory Jackson reports. The ABLE-XR from Tropos Motors is an electric compact utility vehicle (eCUV) designed for carrying loads over short distances, for delivery applications that would normally be reserved for...

Deep Insight

Hydrogen

Nick Flaherty highlights some of the inroads developers are making into rolling out a range of hydrogen-powered vehicles. Many of the engineering challenges with converting hydrogen to electricity to drive a motor in a vehicle have been addressed over the past decade through the development...

In Operation

Urbino 18 electric

This electric bus can be configured for propulsion and recharging in different ways. Rory Jackson explains how it’s used. Solaris Bus & Coach, a Polish manufacturer of buses, shuttles and trolleybuses, has produced and supplied more than 18,000 vehicles across 32 countries, mainly in Europe. Since 2001 it has sought to develop energy-efficient and...

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Insulation

With the need for thermal and electrical insulation in electric vehicles set only to grow, Rory Jackson outlines the options available. With EVs and HEVs being designed now for longer ranges and heavier loads, so batteries are emerging that provide increasing quantities of energy. Most often, that means...

In Conversation

David Richards

The technical manager at permanent magnet supplier MagDev gives Stewart Mitchell some pointers on their design and choice of materials for e-drive motors. With the ever-increasing drive for e-mobility, the development of permanent magnet electric motors and their associated power electronics is now one of the most heavily investigated areas of engineering in the...

Dossier

Lightning Strike electric motorcycle

Stewart Mitchell explains how this road-going machine was developed to take on the ICE competition – at a competitive price. Lightning Motorcycles is an all-electric motorcycle manufacturer that produces the LS-218 ‘superbike’ and the more affordable Strike, which is pitched head-on against gasoline-powered alternatives. Founder of the San Jose, California company Richard Hatfield says...

PS

How Clean are EVs

There’s no doubt that EVs are much cleaner and friendlier to be around than anything powered by an internal combustion engine, as they produce no local emissions (writes Peter Donaldson). They also use energy more efficiently in stop-go traffic, particularly when fitted with regenerative braking systems. Even petrol-diesel electric hybrids allow the engine to be...

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Cables

There is a complexity to producing cables for EVs that some may find surprising. Rory Jackson has the details. The importance of cables for channelling power and data throughout electric and hybrid vehicles over thousands of hours cannot be overstated. However, before selecting and specifying cable requirements, the mechanical stresses they...

Show Report

Electric & Hybrid Vehicle Technology Expo Europe 2019

Rory Jackson was on hand to investigate some of the key product launches and showcases at this recent show in Germany. The Electric & Hybrid Vehicle Technology Expo Europe 2019 was co-located with The Battery Show Europe 2019, and took place in the automobile hub of Stuttgart, Germany, in May. It drew together more than...

In Operation

E-Kotug tugboat

A desire to cut maintenance costs prompted the development of this hybrid version of an existing tugboat. Rory Jackson reports. The E-Kotug is a diesel-electric tugboat owned and operated by international towage services provider Kotug Smit Towage. It is a hybrid-powered version of the Dutch company’s dieselpowered Rotortug design, which features three 360°...

Dossier

Protean Electric PD18 in-wheel motor

Protean’s PD18 has a crucial advantage over other in-wheel motors – it can be retrofitted to existing vehicles. Wayne Ward reports. Pure electric vehicles are rapidly changing from being a niche purchase to one that will soon become commonplace. With the imperative that legislation places on the car...

Deep Insight

Supercapacitors

Nick Flaherty looks at the latest developments in supercapacitor technology for e-mobility systems. Batteries are the go-to technology for powering electric vehicles of all kinds, but supercapacitors (also known as ultracapacitors) are increasing in capacity and performance to become a viable alternative in some applications.  Supercapacitor technology is already well-established in...

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Axial flux motors

Axial flux motors have many EV design advantages over their radial flux counterparts, as Nick Flaherty explains. A new type of motor is gaining traction in the e-mobility sector – the axial flux type. For many years they have been used in stationary applications such as elevators and agricultural machinery, but over the past decade a number of developers have been working on improving...

Dossier

John Deere 944k Hybrid Wheel Loader

Peter Donaldson reports on the design and development of this bulk material mover, the first in its class to become commercially available. In construction and mining, wheel loaders move material in bulk, often scooping it from piles with a bucket and then lifting and dumping it into a truck or crusher. Most are powered by diesel engines coupled to...

PS

Hydrogen fuel cells

There is something of an ongoing debate in the world of e-mobility as to hydrogen’s place in the energy ecosystem (writes Lawrence Butcher). While manufacturers such as Toyota are throwing their weight behind the fuel, and actively marketing fuel cell electric vehicles (FCEVs), others such as...

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Testing and simulation systems

Rory Jackson explains how various test methods work, why they are important and how EV developers can set up their own facilities. Throughout the course of electric and hybrid vehicle development, it is important to remember that the overall system consists of a number of different parts, each in need of...

Digest

Xing Mobility Miss R

Modular, immersion-cooled batteries are key to this EV’s startling range of applications. Lawrence Butcher reports. Xing Mobility is a Taiwanbased EV company with a slightly unconventional approach to powertrain technology that sets it apart in an increasingly crowded market. Through its two technology demonstrator vehicles, the Miss E and the Miss R – the first of which is...

In Operation

EVIE Street Sweeper

Rory Jackson explains what went into developing this battery powered road sweeper. Integrating a zero-emissions powertrain into a street-sweeper. vehicle makes sense for a number of reasons. The principal purpose of such vehicles – to maintain a clean environment in cities and towns, without...

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Battery management systems

BMS technology is still evolving, so EV designers need to know the nuances of incorporating one into an electric powertrain. Nick Flaherty reports. A battery management system (BMS) is key to the reliable operation of an electric vehicle. The functions it has to handle vary from balancing the voltage of the battery cells in a pack to monitoring temperature and...

Deep Insight

Artificial Intelligence

Nick Flaherty looks at the latest advances in – and uses for – AI in the electric vehicle market. There are many uses for machine learning and predictive algorithms, often combined as Artificial Intelligence (AI), in the development and operation of electric vehicles. AI techniques can be used as part of...

Deep Insight

Uniti One

Lawrence Butcher reports on how a Swedish start-up plans to design and manufacture a market-ready EV from the ground up. If one looks across the automotive EV market, it seems barely a week goes by without one company or another announcing that it will revolutionise the electrification of...

Dossier

Phi-Power PHI301 axial flux motor

Lawrence Butcher investigates the technology and engineering behind this compact but powerful motor design. Something of the new kid on the block in the world of electric machines is the axial flux motor. It is a topology which in recent years has seen increased adoption in many e-mobility applications, with the arrival of..

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The Gradual Evolution

After a promising start in the closing decade of the 19th century, the development of electric road vehicles – and to a lesser extent, the adoption of electric power in other spheres of transport – has been a slow process (writes Lawrence Butcher). The main stumbling block has been the means of storing or generating electricity. Range has always been a challenge, with battery technology lagging behind the...

Show Report

Electric & Hybrid Vehicle Technology Expo 2018

Lawrence Butcher rounds up some of the innovation highlights at this show – the largest such event in North America. The annual EV and Hybrid Technology Expo returned to Novi, Michigan, in September 2018, with a host of companies displaying a range of...

Show Report

Electric & Hybrid Marine World Expo 2018

Rory Jackson reports on some of the latest developments in maritime propulsion technology that were on show at this pre-eminent exhibition. Taking place in the RAI Amsterdam Convention Centre, the Electric & Hybrid Marine World Expo is the largest aquatic propulsion trade show in the world. This year’s event was the biggest yet...

Deep Insight

Power Semiconductors

Nick Flaherty reports on how new semiconductor technologies with wider bandgaps will improve the efficiency of electric powertrains. Most power systems for electromobility use semiconductor devices built using a silicon process, but new technologies are maturing that provide higher efficiency and so dissipate less...

Dossier

Volabo ISCAD motor

Lawrence Butcher talks to two of Volabo’s founders about their concept for a traction motor that runs off a mere 48 V. t is generally accepted that in order to use an electric traction motor in a vehicle, where a relatively high power output is...

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Thermal Management 2018

Nick Flaherty explains the issues surrounding the design and manufacture of temperature control systems for electric powertrains. Thermal management is a key part of the design and construction of an electric platform, whether it be ground-based or airborne. The thermal performance of the electronic control system, battery management system and battery packs determines...

In Conversation

Steve Doyle

Ricardo’s head of hybrid and electrical systems tells Lawrence Butcher about the EV projects on the company’s books at the moment. Anyone who has been involved in the development of internal combustion engines will know the name Ricardo. The company, founded in 1915 by pioneering engineer Harry Ricardo, has been instrumental in...

Dossier

Pipistrel Alpha Electro

Lawrence Butcher explains how this electric two-seater, airworthy certified aircraft was developed and how it acts as a pointer to the future. Electric aircraft are by no means a new invention: the first recorded electric powered flight was in 1973, by...