The Grid

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Nestech takes rapid prototyping of motor cores to a new level

As electrical machine manufacturers strive to squeeze ever more efficiency out of motors and generators, there is a growing need for rapid prototyping to support tests of new core geometries in hardware form to confirm they perform in the way simulations say they should, writes Peter Donaldson.

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All-new Mercedes-Benz G 580 with EQ Technology possesses uncompromising off-road capabilities

The all-new Mercedes-Benz G 580 with EQ Technology (combined energy consumption: 30.3-27.7 kWh/100 km | combined CO₂ emissions: 0 g/km | CO₂ class: A | UK figures may vary)1 is fully in keeping with the tradition of the model series established in 1979. Like the conventionally powered models, it is based on a ladder-frame concept, a selectable LOW RANGE off-road gear reduction system, independent front suspension and a rigid axle at the rear.

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Bosch chooses DELO adhesives for mild-hybrid system

With 48 V batteries able to reduce vehicle carbon emissions by up to 15%, Bosch offers manufacturers a powerful solution with its mild-hybrid battery. An adhesive from DELO plays a substantial role in its integration.

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Comau joins zero-defect cell-production project

Comau has joined a pan-European energy transformation initiative in the field of e-mobility in support of the BATTwin project. The company will work with the project’s partners to identify and define crucial data parameters, hardware, software and digitalisation technologies that can be used to meet the goal of zero-defect cell production.

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E-Mobility Engineering partner’s The Magnetics Show North America

The Magnetics Show is a commercial exhibition and technical conference combined. Featuring technical sessions, two conferences, 50+ speakers and 100+ exhibitors, this one-of-a-kind event is this year’s focal meeting point for the entire magnetics industry, held at The Pasadena Convention Center, California on 22-23 May.

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JLR powers up zero emissions charging on the go

JLR has partnered energy storage start-up Allye Energy to create the Battery Energy Storage System (BESS) to provide zero emissions power on the go. A single Allye MAX BESS holds seven second-life Range Rover and Range Rover Sport PHEV battery packs, which can be removed easily from a vehicle and slotted into customised racks without requiring additional processing.

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The Battery Show and Electric & Hybrid Vehicle Technology Expo Europe welcomes industry leaders

The Battery Show Europe and Electric & Hybrid Vehicle Technology Expo Europe, held at the Messe Stuttgart, Germany, has unveiled its comprehensive Conference agenda, spanning three days of sessions. These sessions will spotlight key topics driving the European advanced battery and H/EV industry forward.

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Bel Fuse adds 800 V to its range of fuses

Bel Fuse has expanded its range of fuses for electric and hybrid vehicles with a complete line of 800 V offerings, complementing its 500 V and 1,000 V products. The fuses come in a variety of formats and mounting options, and they are suitable for operating temperatures of -40 C to 100 C, with some featuring a range of up to 125 C.

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Luxinar spotlights laser applications for battery cells to cars

Luxinar will showcase its laser applications for every stage of the battery production process at The Battery Show Europe, staged in Stuttgart, Germany, on 18-20 June. The company will present its CO2 laser sources and femtosecond lasers that can shape battery cells and refine electronic components for the first time at stand 4-G58.

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Why design-for-manufacture could make Traxial axial flux motors go mainstream

Touted as the future of EV propulsion, axial flux motors are more compact, lighter and offer higher power and torque densities than their radial flux counterparts. Until now, they have been exceedingly hard to build but Traxial, a subsidiary of Magnax, is

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Thermal Management Expo North America opens in April

The flagship event of the global Thermal Management Expo portfolio, Thermal Management Expo North America is a unique, free-to-attend exhibition and conference that connects senior engineers and key decision-makers with suppliers specialising in thermal systems and materials. Co-located with Ceramics Expo, the event will take place from April 29 to May 1, at Suburban Collection Showplace in Novi, Michigan, USA.

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Rimac Technology to provide high-voltage batteries for BMW

As part of its ongoing mission to push the boundaries of EV technology, Rimac Technology is embarking on the next stage of development by delivering greater volumes of advanced battery systems. This collaboration with BMW Group marks a significant milestone for Rimac Technology, as it represents the largest and most ambitious project the company has undertaken to-date.

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First airfield-to-airfield eVTOL flight with recharging

Skyfly and AeroVolt are working on the first electric vehicle take-off and landing (eVTOL) flight in the UK between two airfields with electric charging points, writes Nick Flaherty. AeroVolt is installing a network of aircraft smart chargers around the UK at airports and aerodromes. It currently has five operational sites and aims to have 24 running by the time deliveries of the Skyfly Axe eVTOL begin in 2025, with plans in place for over 60 sites.

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Altilium and Talga team up to recover graphite from waste EV batteries

Altilium, a UK-based clean technology group, is partnering battery materials company Talga Group to recover graphite from old electric vehicle (EV) batteries to produce a battery-grade product for use in new anodes.

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Sion powers ahead with its Licerion battery tech

In the seemingly eternal quest for greater energy density in batteries, one of the most promising lines of development is the lithium metal battery, in which the conventional graphite anode is replaced by a pure lithium metal foil. This is the approach that Sion Power is taking with its Licerion battery technology, as CEO Tracy Kelley explains to Peter Donaldson, bringing us up to speed with the company’s progress.

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Tests find Metis battery sensor detects thermal runaway faster than others

Metis Engineering has shared details of a publication by Sandia National Laboratories in the Journal of the Electrochemical Society. Tests found the Cell Guard sensor detected a thermal runaway incident seven minutes faster than other reported evaluations.

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Sector coupling potential demands secure communications

Beyond reductions in local air pollution and fossil fuel consumption, EVs could also make an important contribution to societal energy efficiency through participation in sector coupling. This is the integration and coordination of different energy sectors – such as electricity, heating, cooling and transport – with the goal of optimising the use of renewable energy sources and improving overall energy efficiency across all of those sectors.

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NASA tech lands for brake systems

Orbis Brakes in the US has licensed a NASA-patented technology for lightweight braking systems in electric vehicles, writes Nick Flaherty. The revolutionary brake disc design is at least 42% lighter than conventional cast-iron rotors, with performance comparable to much more expensive carbon-ceramic models.

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Herrmann Ultraschall boosts power of welding

With the Ultrasonic Power Stack 12.000, Herrmann Ultraschall has developed an expansion for the ULTRASAFE W welding machine, which increases its power while reducing cycle times. This increases the maximum welding force of the machine to 10,000 newtons, so even high-voltage cables with cross-sections of up to 150 mm² can be welded reliably.

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Resting boosts lithium-metal battery cells

Researchers have found a key way to extend the life of next-generation lithium-metal batteries, writes Nick Flaherty. Lithium metal cells can double the range of EVs on a single charge and this is a crucial technology for solid-state cells. The researchers at Stanford University found a low-cost approach, which was to simply drain the battery and let it rest for several hours. This restored battery capacity and boosted overall performance.

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Siemens enables simultaneous fast charging of four EVs

Siemens Smart Infrastructure has rolled out an additional variant of its SICHARGE D electric vehicle (EV) fast charger, with a maximum output of 400 kW. Designed for future-proof EV charging, the SICHARGE D dispenser enables up to four vehicles to be charged at the same time with only one grid connection, optimising times for customers, and delivering cost and space savings for charge point operators (CPOs).

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FEV software detects and prevents partial discharge early on

FEV has developed PD-HVX (Partial Discharge – High Voltage X) for the early detection and prevention of PD in high-voltage electric-drive units (EDUs). PD can cause damage to the insulation in modern EDUs, and in the worst-case scenario this can result in total failure of the vehicle.

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Audi’s more powerful & smarter HV battery

The completely newly developed high-voltage battery (HV battery) is largely responsible for the longest electric range in the current Audi portfolio. With an impressive range of 625 kilometers (388 mi), the Audi Q6 e-tron1 is highly suitable for everyday use, making it one of the models with the longest range in its segment.

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Hybrid electric propulsion passenger aircraft

A European project is developing a new propulsion system for medium-range aircraft with up to 35 passengers, writes Nick Flaherty. Several Fraunhofer Institutes and Brandenburg University of Technology Cottbus-Senftenberg, under the leadership of Rolls-Royce Germany and other partners such as research institution ACCESS, are collaborating on the hybrid electric-propulsion system.

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Cell-to-pack architecture for fast charging

StoreDot has developed a cell-to-pack architecture for its silicon-based fast-charging batteries, writes Nick Flaherty. The I-BEAM XFC is a patented cell design that accelerates the integration of extreme fast charging (XFC) into EVs using StoreDot’s proprietary 100in5 electrode technology. The silicon anodes enable charging for 100 miles of range in just five minutes.

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Polymer safety boost for lithium battery cells

Researchers in Korea have developed a polymer separator to boost the safety of lithium-ion battery cells, writes Nick Flaherty. Separators composed of polyolefins, a type of polymer, can be employed to keep the anode and cathode apart to prevent an internal short circuit. However, these separators can melt at higher temperatures, and the inadequate absorption of electrolytes can result in short circuits and diminished efficiency.

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Volvo Cars partners with Breathe for next-gen fast-charging

Volvo Cars has partnered Breathe Battery Technologies (Breathe), becoming the first car company to gain access to the latest version of its patented, algorithm-enabled charging software. By integrating Breathe’s software into its in-house developed

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ENNOVI unveils flexible prismatic battery system

ENNOVI has launched the CellConnect-Prism, a prismatic battery cell contacting system that aims to redefine the connectivity and efficiency of battery modules. The product gives engineers flexibility by enabling the seamless integration of individual prismatic cells to create larger battery modules, or advanced cell-to-pack (CTP)

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The home of foam: accelerate your automotive products

Foam Expo, the largest, free-to-attend trade fair and conference for foam products and manufacturing in North America, is returning for its seventh edition from June 25-27, 2024, in Novi, MI. Register to attend and you’ll gain easy access to the co-located Adhesives & Bonding Expo taking place in the same hall.

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Viritech is ready to run with hydrogen powertrain

Viritech has launched the 60 kW VPT60N Ready to Run powertrain for OEMs, Tier 1 suppliers and research bodies, enabling the rapid deployment of hydrogen fuel-cell electric vehicles. The complete powertrain includes the fuel cell, hydrogen storage, energy store, power electronics, e-machine and transmission. It is suitable for cars, light commercial vehicles and off-highway applications.

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Tackling battery welding challenges with new beam-shaping techniques

A new beam-shaping welding technology has been developed by Cailabs with the aim of significantly improving accuracy and efficiency in the construction of electric mobility parts. This is key to the construction of the battery assembly and is often important for other parts of the vehicle, such as motor hairpins or battery cases.

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AKM rolls out current sensor with 100 ns response time

Asahi Kasei Microdevices Corporation (AKM) has started mass production of the CZ39 series of coreless current sensors, which it says are well-suited to electric vehicles (EV) due to their 100 ns response time, low heat generation and continuous, high-accuracy current detection, even in noisy environments.

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Lead-less transistor packaging

Alpha and Omega Semiconductor (AOS) has developed lead-less packaging for its automotive grade 80V and 100V MOSFET transistors for two and three wheelers, writes Nick Flaherty. The lead-less packaging is a key step in making battery packs and brushless DC motors smaller in two and three wheel scooters. Removing the leads inside and outside the package helps to lower the resistance to 1.25 mOhms and 1.7 mOhms, giving lower losses and allowing higher efficiency for light vehicles.

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Spark connections: Fuel your automotive applications

Adhesives & Bonding Expo, the largest, free-to-attend trade fair and conference for industrial bonding products and manufacturing in North America, is returning for its fourth edition from June 25-27, 2024, in Novi, MI. Register to attend and you’ll gain easy access to the co-located Foam Expo taking place in the same hall.

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Combining machine learning and electrochemical models

Eatron Technologies and About:Energy are developing a decision-engine for battery management systems (BMS) that combines machine learning and electrochemical models, writes Nick Flaherty. The aiMAGINE project aims to use machine learning frameworks in the BMS to extend the life of a battery pack in electric vehicles and scooters.

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Webasto High Voltage Heaters offer speed, efficiency and battery optimisation

Webasto offers three electric High Voltage Heaters (HVH) with 10-12 kW of power for electric cars, trucks, buses, construction machinery and special vehicles. The adjustable HVH 100 Compact, HVH 100 Compact+ and HVH 120 heaters are no

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DuPont’s resin helps extend the life of liquid cooling systems

DuPont AmberLite EV2X resin helps extend the life of an EV’s glycol coolant, coolant loop components and ion exchange filter. It reduces glycol maintenance requirements by offering enhanced thermal stability and excellent operating characteristics, compared with standard ion exchange resins on the market. Consumer demand for greater range, faster charging, larger vehicles and more energy-dense batteries is increasing temperatures within EVs, creating new challenges for vehicle manufacturers. Many are turning from air cooling to liquid systems that use glycol coolant to manage high temperatures.

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ChatGPT for battery chemicals

A team of researchers led by the University of Michigan in the US is developing a generative AI model to produce new molecules for batteries, writes Nick Flaherty. The machine learning framework will be developed using 200,000 node hours on the Polaris, a 34-petaflop supercomputer at Argonne National Laboratory.

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AURUM thermoplastic polyimide offers Tg of 245 C

Electrical breakdown of high-temperature insulation materials can be prevented by using thermoplastic polyimide (TPI), a high-performance polymer. This is important with the transition to electric vehicles, with polymers that offer higher electrical and thermal properties being sought. To enable faster charging and travel over longer distances, electrical breakdown must be prevented by high-temperature insulation materials.

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RAD Propulsion powers electric commuter boat

RAD Propulsion and Stephens Waring Design have teamed up on a project to launch a 26 ft electric commuter boat in the autumn. Stephens Waring’s client requires an electric-powered vessel offering solid performance and dependability.

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IoTecha and Software République fire up Mobilize Powerbox

IoTecha, a provider of smart charging solutions for electric vehicles, has developed the Mobilize Powerbox, a smart, secure, bidirectional AC EV charger, with Software République. IoTecha’s IoT.ON is an integrated platform consisting of software, hardware and cloud components for the smart charging infrastructure and power-grid integration of all kinds of EVs, including light-duty vehicles, trucks and school buses.

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Detecting test-gas leaks in EV battery production

A leading battery manufacturer for the automotive industry is using test-gas leak-detection systems from Zeltwanger Leak Testing & Automation, which is equipped with complete solutions from Pfeiffer Vacuum.

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Improving the accuracy of EV chargers

The technology behind EV charging is becoming increasingly complex, and as infrastructure manufacturers push the boundaries to develop next-generation solutions that deliver power faster and more efficiently, one of the crucial areas of focus is the method of power metering.

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Bloomy rolls out compact battery simulator

Bloomy Controls has launched the Desktop BMS HIL Test System, a small, compact and transportable system for users to simulate battery cells safely for development projects.

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Lunaz upcycled electric refuse trucks to operate across London

Lunaz begins 2024 in a strong position to continue its journey towards producing 1,100 upcycled electric vehicles (UEVs) a year, with confirmation that its upcycled refuse trucks achieve the highest five-star Direct Vision Standard (DVS) rating for driver visibility.

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Smart switch protects 800V battery packs

Kyocera AVX has developed a smart semiconductor switch for EV battery pack designs, writes Nick Flaherty. The switch supports voltage levels up to 930 V for 800 V battery packs and is able to withstand short current events up to several thousand amps. Using a scalable design, the switch can be adapted to different power classes up to 640 kW continuous performance and provides both a safety cutoff and also support for higher charging rates.

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Magna awarded specialized eDrive system business with North America based OEM

Magna is growing its electrification customer base with a newly awarded contract from a North America-based OEM to supply a specialized primary rear eDrive system for one of the company’s high-end niche vehicle platforms. The award reinforces Magna’s commitment to supporting the automotive industry’s short and long-term transformational needs.

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LFP cells charge in six minutes

DESTEN has developed the first Lithium Iron Phosphate (LFP) cell that can charge in just six minutes at 6 C writes Nick Flaherty. The 160 Wh/kg pouch cell developed by DESTEN is capable of charging from 20% to 80% SOC in six minutes at a charging rate of 6 C. Moreover, the LFP chemistry means the cell is intrinsically safer than lithium ion cells.

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New Renault Master E-Tech electric’s WLTP range – up to 460 km

Renault has chosen two batteries optimised for capacity, size and mass, combined with in-depth work on aerodynamics and a brand-new innovative platform. The van comes with a choice of two energy storage capacity ratings: 40 kWh and 87 kWh. These two packs are built into a single casing and designed for driving requirements in cities as much as in suburbs. And they do not hamper the vehicle’s payload capacity – which is an essential criterion in this segment.

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Ascend Elements Targets 90% Reduction in EV Battery Material Carbon Footprint By 2030

New Life Cycle Assessment (LCA) Compares Carbon Emissions of NMC 622 Cathode Material Made with Mined Metals Vs. NMC 622 Hydro-to-Cathode® Battery Materials Made with Recycled Materials Using its patented Hydro-to-Cathode® process and recycled materials, Ascend Elements can today manufacture new EV battery material (NMC 622 cathode) at a 49% reduction in carbon emissions compared to traditional cathode manufacturing processes that rely on primary materials from mining.

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In wheel motor development

YASA is working with Domin on an in-wheel motor system that weighs under 2 kg, writes Nick Flaherty. The project with Cranfield University in the UK will create a patented in-wheel motor design using YASA’s axial flux motor and Domin’s digitally controlled hydraulic active suspension. The aim is to develop a motor system that is ten times lighter than the current 12 kg motor package design.

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Successful test of aircraft rim motor

Duxion Motors has successful ground tested its patented eJet Motor for electric aviation, writes Nick Flaherty. The successful ground testing of the scaled prototype at Summerside, Prince Edward Island, Canada, included both low-speed and high-speed testing.

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Elkem develops iron-silicon powder for 3D printing of e-motor parts

Elkem has developed a new, specialised iron-silicon powder, which may allow the 3D-printing of components for electrical motors, with partners through an EU-funded project.

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Heraeus reduces gap in stacked rare-earth magnets in ‘game-changer’ for motor design

Heraeus High Performance Coatings has launched an innovative process for laminated rare-earth metal magnets that boosts performance and manufacturing efficiency, which is crucial for high-power electric motors.

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Quantix Ultra offers flame protection at 1,200 C

A new material called Quantix Ultra, produced by Freudenberg Sealing Technologies, offers improved fire protection in electric vehicle (EV) drives, having resisted temperatures of up to 1,200 C during testing.

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Amprius rolls out high-density SiCore batteries with extended cycle life

Amprius Technologies, a manufacturer of next-generation lithium-ion batteries, has unveiled its new SiCore product platform, with the aim of revolutionising electric mobility. The company has also branded its existing silicon nanowire platform, SiMaxx, with its current product range of up to 500 Wh/kg and 1,300 Wh/L energy density.

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Comau to design battery testing strategy for Fastest project

Automation solutions provider Comau is tasked with designing the digitalisation and implementation strategy for Fastest, an EU project that aims to accelerate the development of batteries that are safer, more reliable and durable. Turin-based Comau, a Stellantis company, will leverage its long-standing expertise in digitalisation, process simulation and electrification to accelerate the testing and verification of automotive and stationary batteries.

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Schaeffler’s high-performance ball bearing offers better range

They literally move the world as no powertrain can do without bearings ─ be it electric cars, hybrid vehicles or internal combustion engines. Schaeffler has now developed a special high-performance ball bearing with an integrated centrifugal disc.

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Littelfuse offers fast-response overtemperature detector for Li-ion battery packs

Littelfuse, a Chicago-based industrial technology manufacturing company, has launched an overtemperature-detection platform, designed to transform the management of lithium iron (Li-ion) battery systems.

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Adhesives: essential EV enablers

Adhesives are used in vehicles of all kinds, but they are particularly essential in electric vehicles (EVs) because they perform key functions within battery packs and help save weight in body structure, translating into performance and energy efficiency, as David Fetterman, PPG Industries’ global segment director for adhesives and sealants, explains to Peter Donaldson.

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Freudenberg PM’s Battery Pack Liquid Absorbers

Freudenberg Performance Materials has developed an absorbent pad technology for installation inside electric vehicle (EV) battery packs (and outside their modules). These Battery Pack Liquid Absorbers are intended to enable passive climate control through long-lasting moisture management, with repeatable absorption and redrying cycles.

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Dust busters

Dust explosions are a major hazard in many industries, and there are about 2,000 occurrences in factories and refineries across Europe per year. Battery electrode manufacturing is exposed to this type of risk and must take precautions that comply with explosive atmosphere (ATEX) directives.

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Charging ahead with Nyobolt’s SiC EVSE DC charger

Nyobolt has developed electric vehicle supply equipment (EVSE) for off-board DC fast chargers that integrates silicon carbide (SiC) power transistors. Although the UK-based company most recently made headlines for its fast-charging battery technology, showcased in its eponymous EV...

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Kennemetal’s additively-manufactured boring tool

Kennametal has created a new machining tool leveraging its "KENionic" technology, which is aimed at tackling industry requirements on the precision production of motor and transmission housings.

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Tata Passenger Electric Mobility launches its first Pure EV architecture – ‘acti.ev’

Tata Passenger Electric Mobility (TPEM), have introduced its first advanced Pure EV architecture – acti.ev (pronounced as active). acti.ev stands for (Advanced Connected Tech-Intelligent Electric Vehicle). The acti.ev architecture is based on the key pillars of Performance, Technology, Modularity, and Space Efficiency and consists of four layers:

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Modular plug-and-play rectifier

OmniOn Power has developed a modular 30 kW rectifier in a 19 in rack format to build EV fast chargers (writes Nick Flaherty). The EV100H3NK and EV101H3N1K AC-DC variants of the rectifier design have efficiencies of up to 96% and integrate CAN automotive comms protocols. Up to 12 rectifiers can be used in parallel in a 19 in rack to build fast-charging 360 kW systems quickly and easily.

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Mini-spoiler alert for faster flight

Researchers at the University of Bath are investigating how deploying spoiler-like devices called mini-tabs could help electric aircraft fly faster (writes Nick Flaherty). Mini-tabs can counteract the damaging vibrations caused by whirl flutter that occurs at high flight speeds. Maxon has provided the motion systems to test the effectiveness of the mini-tabs on a novel wind tunnel test rig.

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Refuelling pump seals the FC deal

Researchers in the US have developed a sealed compressor using a linear motor for refuelling hydrogen EVs (writes Nick Flaherty). The hydrogen compressor, developed at the Southwest Research Institute (SwRI), can improve the efficiency and reliability of hydrogen compression used in the refuelling of fuel cell EVs (FCEVs).

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DiL system cuts physical testing

Horiba MIRA has opened a driving simulator centre in the UK with driver-in-the-loop technology (writes Nick Flaherty). The £4 million centre aims to help established car designers, start-up vehicle manufacturers and Tier 1 suppliers to develop new vehicles.

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CUI Inc, announces expansion of AC-DC power supplies

CUI Inc, a Bel group company, announced the addition of three, chassis mount ac-dc power supplies housed in compact metal cases with the VGS-500, VGS-350D, and VGS-200E series line of products.

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Amada Weld Tech highlights TP-AWS3-A touchscreen panel for weld monitoring

highlights their latest advancement in laser weld monitoring technology, the TP-AWS3-A Touchscreen Panel for Weld Monitoring. In today’s global commerce traceability and accountability is of utmost importance, an integrated, accessible, and all-inclusive monitoring system is necessary.

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Altran Magnetics’ AXV200 Series DC Contactor

DC contactors are at the heart of all types of modern transportation, where efficiency and reliability is paramount. Altran Magnetics are excited to announce their new AXV200 Series DC Contactor, a marvel of engineering, designed to switch power in the next generation of electric and hybrid vehicles.

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Structural carbon fibre research

Researchers at Chalmers University in Sweden have shown how the manufacturing of carbon fibres can be tailored for developing structural batteries (writes Nick Flaherty). They worked with Carbon Nexus at Deakin University, in Australia, to build a variety of fibres that are strong enough to use in vehicles but can also store significant amounts of energy. However, the properties of the carbon fibre vary depending on the process parameters and which precursor is being used. Some types of carbon fibre can be very stiff, but have a far too low a storage capacity, and vice versa.

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Comau and Lina Energy unveil solid-state battery manufacturing system

Comau and Lina have designed a scalable manufacturing solution for solid-state sodium-metal-chloride batteries. The design allows solid-state sodium battery supplier Lina to automate its battery production process. Comau and LiNa...

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Parker Chomerics announces thermal gels for high-vibration applications

The Chomerics division of Parker Hannifin Corporation has launched two fully cured dispensable thermal gels. The new Therm-a-Gap Gel 35VT and 50VT conduct heat away from electronics to heat sinks or enclosures, and are said to perform reliably in both vertical and high-vibration applications.

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Burger Group launches actuators for thermal management

Automotive products developer Burger Group has developed a range of electromechanical valve actuators for tackling the specific requirements of controlling active thermal management systems in vehicles (writes Rory Jackson). Stefan...

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Detectors do more using less

Nisshinbo Micro Devices has launched two voltage detectors that are designed to provide higher accuracy in ECUs and BMSs using fewer components (writes Nick Flaherty). When monitoring high voltages, it is crucial to consider the drawbacks of using traditional low-voltage detectors with an open drain output. The NV3600 and...

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Lotus launches EV charging solutions

Lotus has launched its own EV charging solutions including an ultra-fast DC charger, power cabinet and a modular unit for charging up to four vehicles at once. The EV charging solutions include a liquid-cooled all-in-one DC charger that offers charging of up to 450 kW. For example, with the Lotus Eletre R, it can add up to 88.5 miles or 142 km of range after about 5 minutes of charge. A 10-80% charge can be achieved in 20 minutes to give a range extension of 74 miles or 120 km from a 5 minute charge.

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Battery advance extends RV range

US start-up Grounded has developed a modular electric recreation vehicle (RV) with a range of 250 miles (writes Nick Flaherty). The G2 increases the range from the 100 miles of the original version, the G1, by using a larger and more efficient battery pack.

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How Camfil cleans up the battery production process

Battery anodes and cathodes are typically made from slurries of active chemical powders and supporting substances such as binders and solvents applied to foil substrates, before being dried, cut and combined into ‘jelly rolls’ or laminates to form the core components of cells (writes Peter Donaldson). The process inevitably...

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Northvolt develops sodium-ion battery validated at 160 Wh/kg

Following a breakthrough in technology, Northvolt adds sodium-ion to its cell portfolio, enabling the expansion of cost-efficient and sustainable energy storage systems worldwide. The cell has been validated for a best-in-class energy density of over 160 watt-hours per kilogram at the company’s R&D and industrialization campus, Northvolt Labs, in Västerås, Sweden.

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PV system proves a good catch

A start-up is working in Africa to electrify fishing boats (writes Nick Flaherty). VoltaViewAfrica was set up by a professor from the Fraunhofer research institute in Germany. Photovoltaics generate electricity, which is stored in mobile, portable lithium batteries that local residents can use as an individual power source which includes powering local fishing boats.

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Recyclus launches waste lithium-ion battery storage solution

Battery recycling business Recyclus Group has developed a solution for the safe storage and transportation of lithium-ion batteries, the LiBox. It is a pallet-sized, steel fabricated box, UN-certified and ADR-compliant. It is rated to a 20 kWh power rating, and can control thermal conditions of up to 2000 ºC.

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Wevo announces heat management materials for inverters

Wevo-Chemie has developed potting compounds and gap fillers for inverters that provide targeted heat removal and mechanical stability. Due to their low ion content, these epoxy resin and silicone-based materials protect against electrochemical corrosion as well as providing provide reliable electrical insulation.

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Solar supplement for hybrid truck

Scania has shown a prototype of an electric truck that uses solar panels to provide additional power for propulsion (writes Nick Flaherty). The truck is a regular 100 kWh Scania plug-in hybrid connected to a trailer with 200 kWh of additional batteries as a power bank. These are connected to the solar panels. “When we first began thinking about this, our starting point was the lithium-ion batteries used in battery-electric trucks,” said Eric Falkgrim, a technology leader at Scania’s Research and Innovation department and the project manager for the truck. “In the time that Scania has been working with that technology, we’ve seen the batteries become lighter, cheaper and more energy-dense.”

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Impact announces bespoke batteries for Alexander Dennis e-buses

Impact Clean Power Technology has unveiled battery systems tailored to the next generation of Alexander Dennis buses, the Enviro100EV and the double-decker Enviro400EV. Production of both vehicles has already stared, with deliveries to customers in the UK and Ireland planned for early next year.

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Autocraft takes us through its battery repair process

Autocraft EV Solutions now offers its highly automated and guided Revive battery repair and remanufacture system in service in both static and mobile versions (writes Peter Donaldson). We recently took the chance to discuss the system with Dr Sara Ridley, engineering & quality director of Autocraft Solutions Group, who has seen it through its development and early deployment. Dr Ridley explained what happens when a dealer needs a replacement for a battery in a customer’s car. “They log on to their web portal, which patches them through to ours. They tell us which battery they have a problem with, and we dispatch a replacement with all the packaging and paperwork they need,” she says.

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CSM’s new HV breakout module

As an extension of the HV Breakout Module (HV BM) product portfolio, CSM GmbH presents the HV Breakout Module 3.1 OBC for worldwide analyses of the AC charging processes of electric and hybrid vehicles. For this reason, the module is designed for currents of up to 88 Arms (±125 A). Due to the integrated star connection, one- to three-phase measurements are possible with this HV-safe (per EN 61010) measurement module. A high sampling rate also provides precise measurements during switch-on and switch-off processes.

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Graphene-free liquid cooling

Researchers at Samsung have developed a design for a liquid-cooled thermal management system (TMS) for large lithium-ion battery packs (writes Nick Flaherty). They first built a coupled 3D electrochemical/thermal model of a battery pack that avoids the use of materials such as graphene. Simulation showed that it is the contact resistance that has the greatest impact on the pack’s thermal performance, and the temperature performance across the pack could be determined from a single cell.

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Moulding method for pack covers

Materials firm Sabic has successfully moulded an EV battery pack top cover using low-pressure injection moulding (writes Nick Flaherty). The trial of the process is part of Sabic’s Bluehero initiative to show the manufacturability of large EV battery components using thermoplastic injection moulding. This specific form of...

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LG Chem and LX Hausys announce material for delaying thermal runaways

LG Chem has announced that, together with LX Hausys, it has developed a material that delays battery thermal runaways. Their Special Flame Retardant Continuous Fibre Thermoplastic (CFT) can withstand flames and high pressure for more than 14 times longer than existing thermoplastics.

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Toyota announces 50 kW-class fuel cell module

Toyota has developed a fuel cell (FC ) module with an output of 50kW, which can be installed in lift trucks, agricultural machinery and construction equipment, among others.

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Henkel’s high-performance battery sealing technology

After decades building a reputation for performance and reliability among global OEMs and component suppliers, Henkel has expanded its broad portfolio of adhesives, sealants, and functional coatings to serve EV manufacturers with innovative solutions across the EV segment. When it comes to ensuring the safety and durability of EV batteries, proper sealing is one of the most critical performance factors.

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GKN Automotive unveils new off-the-shelf electric drive unit concept

GKN Automotive has unveiled a plug-and-play e-drive concept designed for niche EV players and conversion companies. GKN says the eCrate concept is the basis for a cost-effective modular e-drive system using market-proven technology in an off-the-shelf format.

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Reliability boost for aluminium cells

Researchers in the US have developed a high-power solid-state battery using aluminium that avoids previous reliability issues (writes Nick Flaherty). The team, from the Georgia Institute of Technology (GATech), worked with Novelis, which manufactures aluminium and is the world’s largest aluminium

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Scania’s rejuvenates battery electric range

Scania has updated its urban battery electric truck range and added a new electric machine (combined electric motor and gearbox) to its line-up. The battery electric urban truck range, originally launched in 2021, has been given a major update in line with Scania’s regional battery electric line-up.

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Cheaper, more efficient MOSFETs

iDEAL Semiconductor has developed a technology that can improve the efficiency and cut the cost of power MOSFETs for e-mobility applications (writes Nick Flaherty). The SuperQ process technology can also be applied to SiC MOSFETs and GaN transistors in the future, said Mark Granahan, CEO and founder of iDeal Semiconductor.

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AES showcases cell-testing models at the US Battery Show

Associated Environmental Systems (AES) showed its All Test Platform (ATP), a fixture designed to support a number of cells within an environmental test chamber of its own manufacture, at the US Battery Show North America in Novi, Michigan (writes Peter Donaldson).

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Quantum jump speeds FC design

BMW and Airbus are using a quantum computer to improve the design of hydrogen fuel cells (writes Nick Flaherty). The two are working with quantum computing company Quantinuum on a design flow that combines quantum and classical techniques to speed up research.

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First Frauscher/Porsche eFantom ready for launch

Porsche and Frauscher Shipyard have presented the first production model of their electric 850 Fantom Air. Equipped with powertrain technology from the forthcoming all-electric Porsche Macan, it uses components of the Premium Platform Electric on which the Macan is based. This includes a permanently excited synchronous electric motor, whose peak power for the eFantom has been limited to 400 kW, and the associated power electronics.

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Comau announces automated production system for NIO e-drive systems

Comau has implemented a turnkey solution to automate the manufacturing of NIO’s next-generation e-drive systems. The company says it ensures fast and reliable co-line production for the EV manufacturer’s third-gen induction and permanent magnet...

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ZF unveils next-generation low-floor e-axle for city buses

ZF’s Commercial Vehicle Solutions division showcased its AxTrax 2 LF electric portal axle for low-floor city buses at the recent Busworld 2023 show. The axle comes with two standalone SiC inverters and an electric control unit. Fitting a similar installation...

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Elinta Motors unveils third-gen 400 and 800 V powertrains

Elinta Motors has launched its third-generation 400 and 800 V systems. The 400 V version is aimed at light to medium-duty vehicles, and features a 160 kW motor and up to 168 kWh with four battery packs.

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Additive manufacturing advance in stator production

Researchers in the US and UK have used additive manufacturing (AM) to develop a 3D-printed motor with materials previously considered too brittle to use (writes Nick Flaherty). The researchers, at the University of Sheffield in the UK and the University of Wisconsin-Madison in the US, have developed a 10 kW prototype motor that they are scaling up to 40 kW for e-mobility applications.

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EaglePicher develops battery technology for Saab Gripen fighter aircraft

Battery power systems producer EaglePicher has announced an award by Saab to design and develop a 24 V, 36 Ah lithium-ion batteries for its Gripen E-series fighter aircraft. They are the first of their kind to be used on Saab’s aircraft.

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Cell proves its worth for eVTOLs

About:Energy has characterised the P45B high-power battery cell from Molicel being used in several eVTOL designs (writes Nick Flaherty). The P45B has a 10C pulse discharge capability and a 3C charge capability but can still provide a 242 Wh/kg nominal specific energy. Its low DC internal resistance is measured by About:Energy at 13.8 mΩ (7.86 mΩ for 0.2 seconds) bodes well for high C-rate use cases, particularly where the thermal management system is constrained.

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Bo releases finalised specification of micro-mobility vehicle, the Bo M

Bo, maker and developer of the world’s most sophisticated urban micro-mobility vehicle, announces the move to production and confirms full launch specifications of the revolutionary Bo M, a new electric vehicle for city riders, which will offer the smoothest and most stable ride of any vehicle in its class.

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Carbon fibre made from sawdust

Researchers at the Bernal Institute in the University of Limerick (UL) are developing processes to create sustainable carbon fibres for car structures and batteries (writes Nick Flaherty). The processes use lignin, which is found in the walls of plant cells and is the second most common carbon material after cellulose.

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Vitesco Technologies develops innovative power module

Vitesco Technologies, a leading international supplier of modern drive technologies and electrification solutions, is developing a power

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Two-step locking in just one push

Yamaichi Electronics has added Connector Position Assurance (CPA) and integrated contact protection to its fourth generation of board-to-cable connector for battery packs (writes Nick Flaherty).

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Helix announces success of aerospace electric propulsion demonstrator project

Motors and inverters manufacturer Helix has announced the completion of its direct drive scalable aerospace electric propulsion demonstrator technology project. Known internally as the XBS, the project ran in partnership with the UK’s Midlands

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Turntide introduces new modular battery pack for off-highway vehicles

Turntide Technologies has announced the launch of the Turntide lithium-ion NMC battery pack. It offers a scalable modular design with greater energy density in a lighter, smaller form factor than the previous Hyperdrive battery line.

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Forsee Power launches ZEN LFP battery system for heavy vehicles

Forsee Power is launching a new high-energy battery system, ZEN LFP, to provide full-day operations to electric buses, trucks, and off-highway vehicles. The ZEN LFP battery system – available in 36 kWh and 55 kWh modules– has been developed by Forsee Power's R&D engineers and will be manufactured in Europe, North America, and Asia-Pacific.

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Zero-emissions barge in world first

Dutch shipping company Future Proof Shipping (FPS) has launched the first hydrogen-powered zero-emissions inland container ship (writes Nick Flaherty). The H2 Barge 1 was developed in partnership with sports company Nike and the BCTN Network of Inland Terminals. The 110 m-long, 11.45 m-wide ship will sail between Rotterdam and BCTN’s inland terminal in Meerhout several times a week.

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StoreDot warns industry over extreme fast charging battery technology

Extreme fast charging (XFC) battery technology developer StoreDot is reiterating its policy of supplying chemistries that ensure minimal battery degradation over an EV’s lifetime. Its announcement is in response to recent industry claims touting fast charge times and extended ranges, which it says often overlook the potential long-term impact on battery health and the resulting degradation in vehicle driving range.

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Potenza Technology announces latest battery management system

Electric and hybrid-electric vehicle systems developer Potenza Technology has unveiled its fifth-generation BMS. The system is fully compliant with ISO 26262 ASIL C. It is compatible with 400 and 800 V battery systems, which can be configured at an application level to enable OEMs to maximise its effectiveness for each use case, from commercial vehicles to hypercars.

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Sabic plastics contribute to electric record-breaking performance

Sabic has provided materials as part of its work on an electric car known as the Genbeta (writes Nick Flaherty). The materials are high-performance thermoplastics that provide more processing flexibility to enhance the car’s aerodynamics, contributing to its acceleration and speed.

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Simulators simplifies e-train design

A new version of the Spice analogue simulator called Qspice can simplify the development of motor control for EV powertrains and other vehicle motors (writes Nick Flaherty). The Qspice simulator has been written by Mike Englehardt, the creator of several versions of the Spice analogue simulator. It can integrate digital elements such as controllers with no performance penalties alongside the analogue power device simulation.

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Parker Lord expands CoolTherm portfolio of thermally conductive materials

The Parker Lord Assembly and Protection Solutions Division of Parker Hannifin Corporation, a leader in motion and control technologies, is pleased to announce the launch of three new products specifically designed for electric vehicle battery systems. With a focus on collaboration, customer service and high quality, Parker Lord provides innovative solutions that meet the design, safety and performance requirements of battery manufacturers.

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Xing Mobility releases cell-to-pack immersion-cooled battery

Xing Mobility has announced the official release of its Immersio cell-to-pack battery, which uses high-nickel cathode cylindrical lithium-ion cells. Xing describes the Immersio as a flexible pack concept that can be customised for various...

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Bel expands RCM Series with dual-output DC-DC converter for railway systems

Bel Fuse has announced the expansion of its RCM Series with the RCM300 dual-output DC-DC converter for railway and transportation systems. The converter delivers 300 W at +24 V/-24 V, the two input ranges covering all common railway batteries. Both outputs are independently regulated, allowing constant regulation even at extreme cross-loads.

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Thyristors save space in charger

Littelfuse has developed a reference design for a 2 MW bidirectional fast charger for commercial vehicles (writes Nick Flaherty). Rather than using MOSFETs, the 12-pulse thyristor stack can support a 2 MW output in a smaller volume with just forced-air cooling. Five 70 kW modules using thyristors that are stacked to provide 350 kW occupy 0.175m³, excluding any pumps and radiators needed for cooling the circuit. For a dual 350 kW charger, the minimum space consumed is a cube with 1.5 m sides and a volume of 3.4m³.

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Webasto’s Next Generation Coolant Heater

Smaller, lighter, more sustainable: The Next Generation Coolant Heater sets new standards for electric high-voltage heaters in terms of installation space and weight. For system requirements that demand particularly high heating performance requirements, Webasto’s high-voltage heaters (HVH) deliver an ideal solution:

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Staubli unveils CharIN-compliant megawatt charging system

Staubli has launched its Megawatt Charging System (MCS), which allows electric commercial vehicles with to be charged at up to 4.5 MW. It has been developed in collaboration with the Charging Interface Initiative (CharIN) and in accordance with its specifications. The system delivers up to 3000 A and 1500 V.

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BMS measures cells in real time

Rather than using algorithms that model the expected performance of battery cells, electrochemical impedance spectroscopy (EIS) measures the current from each individual cell using random pulses to avoid overheating the cell.

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Chroma ATE unveils integrated HIL test bed for battery EVs

Chroma ATE has launched the 8610 battery pack power HIL test bed for testing battery systems and components of new energy vehicles, including the battery module, BMS and cooling/heating system. Various hardware options are available for integration, such as a DC power supply, battery charge-discharge system, digital meter, hi-pot tester, and short-circuit and overvoltage protection devices.

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Zeiss unveils NDT system for battery and EV builders

Zeiss Industrial Quality Solutions has launched its VoluMax 9 titan system for computed tomography (CT) analysis of battery cells and EVs. CT is a non-destructive means of checking that the various steps in the production processes are working as intended, so that sub-components are handled and assembled without errors or damage.

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Calcium shows promise for cells

Researchers in Japan have developed a promising rechargeable calcium metal battery with a long lifetime (writes Nick Flaherty). The prototype is capable of 500 cycles of repeated charging-discharging. As the fifth most abundant element in Earth's crust, calcium is widely available and inexpensive, and has a higher energy density potential than lithium.

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Stellantis and Saft unveil storage battery for EVs and stationary power

A team comprising CNRS (the French National Centre for Scientific Research), Stellantis and Saft have unveiled a prototype of an energy storage battery that integrates the inverter and charger functions to create a battery that enhances the range of BEVs.

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Bentley unveils recreation of the Blower by The Little Car Company

Bentley Motors and The Little Car Company has unveiled a road-legal, 85 per cent scale recreation of the most famous Bentley in the world. ‘Blower Jnr’, a recreation of the 1929 4½-litre Supercharged Team Car No. 2 in Bentley’s Heritage Collection, is the first road-legal car from The Little Car Company and the most sophisticated city car ever built.

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CATL launches superfast charging battery

CATL launched Shenxing, the world's first 4C superfast charging LFP battery, capable of delivering 400 km of driving range with a 10-minute charge as well as a range of over 700 km on a single full charge. Shenxing is expected to considerably alleviate fast charging anxiety for EV users, and opens up an era of EV superfast charging.

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Tool chain for ZEVonUDS standard

Vector Informatik has developed a tool chain for the emerging ZEVonUDS standard for onboard diagnostics (OBD) in EVs (writes Nick Flaherty). The standard, SAE J1979-3, details how OBD data is read from vehicles using an external diagnostics device called a scan tool. This can be used to monitor functions in ECUs that have an influence on vehicle efficiency, and the monitoring functions must be available whether emissions are caused directly by an IC engine or indirectly by generating electricity to charge a traction battery in the vehicle.

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Tecman unveils high-volume anti-thermal propagation pad process

Materials engineering firm Tecman says it has developed a process that for the first time enables high-volume continuous manufacture of framed Anti-Thermal Propagation (ATP) pads. ATP pads are a type of cell barrier that incorporate a physical built-in spacer that surrounds the insulation pad.

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ViscoTec announces flow monitor for analysing process-related viscosity pressures

In the future, users who operate a stand-alone dispenser can monitor and evaluate their pressures in the dosing process. This is made possible by the flowplus-MONITOR QC analysis unit, which can be used flexibly thanks to its two channels...

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Lab allows customised validation

NI has developed a software-defined battery laboratory to speed up the validation of battery systems (writes Nick Flaherty). The lab covers a battery’s lifecycle from r&d to validation, production, second life and re-manufacturing by using different software loads.

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Magna launches modular e-decoupling unit for battery EVs

Magna has announced the start of production of a modular e-decoupling unit to support multiple battery EV programmes for a German premium OEM. The unit is an electromechanical device that disconnects an EV’s...

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Head of Bosch Mobility Solutions talks EV tech

Arun Srinivasan, head of Bosch Mobility Solutions in the UK, says that, as a Tier 1 automotive supplier, the company is well-placed to assess which technologies in which sectors are best placed to reduce the environmental impact of road transport, particularly by eliminating tailpipe emissions (writes Peter Donaldson).

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Solid-state cell is safety-approved

Factorial has become the first company to receive safety certification for a large, 100 Ah solid-state lithium metal battery cell (writes Nick Flaherty). The large-format automotive solid-state cell has received the United...

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Comau developing battery cell formation solutions for Gigabat project

Comau says it will be developing an energy-efficient cell formation chamber as part of its work with Gigabat, a pan-European initiative aimed at supporting the sustainable and ecological transition towards e-mobility...

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ABB unveils HV connector interfaces for heavy-duty EVs

Heavy-duty EV wiring is particularly vulnerable to high engine temperatures, strain, abrasion, vibration, ingress and corrosion, so to protect and stabilise these connections ABB Installation Products has announced...

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ML finds solid-state cell materials

Researchers in the US have used machine learning (ML) to identify new combinations of materials for solid-state batteries (writes Nick Flaherty). The class of compounds, called argyrodites, contains attractive...

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GKN Automotive launches next-generation inverter

Drive systems supplier GKN Automotive has launched its next-generation inverter, to provide OEMs with 800 V EV technology. The inverter, one of three modular elements of GKN Automotive’s eDrive platform, offers...

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Dürr announces new approach to paint shop energy efficiency

Dürr says its EcoQPower system uses energy flows in a completely new way to make automotive paint shop operations as energy-efficient as possible, by allowing plant operators to move towards electrification.

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Littelfuse releases AEC-Q200 Rev E-qualified fuses for automotive-grade applications

Industrial technology manufacturing company Littelfuse has announced a range of AEC-Q200 Rev E-qualified fuses for EV applications. They include thin-film, Nano2, PICO and cartridge fuses...

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A new way to localise defects in vehicle battery packs

Siemens has been explaining how its Simcenter Sound Camera can be used to localise electric arcs and therefore help to repair battery packs. The camera makes use of the fact that an electric arc creates noise. A defective connection between battery cells will create an arc when the pack is tested...

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PowerCo announces dry coating technology for cell production

PowerCo SE is to introduce a new manufacturing process in its battery cell production plants in Europe and Northern America. It aims to industrialise the so-called dry coating procedure in conjunction with printing machine specialist Koenig & Bauer.

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Marelli announces new integrated thermal management module for EVs

Marelli has launched its new integrated Thermal Management Module (iTMM) for EVs, which allows the vehicle's different thermal circuits to be combined into a single component. While EVs generally have a number of heat exchangers, each with a sole function, the iTMM modularises water-cooled heat exchangers such as the chiller or water-cooled condenser using a smart valve arrangement. The valve manages up to...

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Helix develops 650 kW continuous output low-inductance motor for hypercar project

The X-Division of UK-based Helix has announced the SPX177, which it has supplied for a hypercar motor project known as REB. Capable of delivering 650 kW of continuous power, the company says...

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ZF presents ‘ultra-compact’ e-drive for passenger cars

ZF has unveiled its electric concept vehicle, the EVbeat, in which the components of an e-driveline have been optimised and combined into a holistic system. These include an ultra-compact 74 kg driveline with a torque density of 70 Nm/kg, holistic thermal management and cloud-networked driveline software. At temperatures around freezing point, the range in real-world operation...

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Plastics offer key role in designs

Plastics are now able to replace metal for the construction of EV charging stations (writes Nick Flaherty). SABIC has created a concept demonstrator made with 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.

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Global automotive testing Storedot’s extreme fast charging battery cells

StoreDot’s extreme fast charging (XFC) high energy battery solutions for electric vehicles, has obtained outstanding battery performance feedback for the first evaluation and integration A-Samples testing phase of its XFC electric vehicle battery cells.

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PREMO’s BCBM-50KW-001 Module for Air-Cooled EV Charging Stations

At the heart of Premo’s innovation lies a compact 50KW transformer set meticulously engineered to meet the demanding power requirements of modern EVs. Housed within a sleek 300 x 174 x 100 mm aluminium casing, this high-performance transformer boasts remarkable efficiency, delivering power with over 99% efficiency. This exceptional efficiency ensures minimal power loss, reducing […]

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Cell simulator for latest monitors

MicroNova has enhanced its Cell Module Controller (CMC) simulator to support the latest high-accuracy battery cell monitors and balancers from Texas Instruments, or TI (writes Nick Flaherty). The NovaCarts CMC simulator has a daisy-chain comms interface to the bridge device on the master board of the BMS or the master control unit to provide precise […]

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Yamaha’s new PW-XM flagship eMTB drive unit

The new PW-XM is the lightest drive unit in the range, and its launch 30 years after Yamaha invented the eBike underlines just how far this zero-emission technology has progressed. Aimed at the high-end eMTB market, the PW-XM features a specifically-designed magnesium housing that keeps its overall weight down to just 2.6 kg...

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NIO unveils its first smart electric tourer for Europe

NIO has announced its first EV tourer for Europe, the ET5 Touring. The ET5 Touring uses NIO’s proven dual-motor all-wheel drive system, comprising a 150 kW...

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Sensor aims to boost range of EVs

LEM has developed a current sensor with resolution of 0.1% that can boost the range of EVs. The CAB 1500 uses an open-loop fluxgate transducer to deliver the resolution and a total error of 0.5%.

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EV battery charger draws on solar power

SolarEdge Technologies has unveiled its new bidirectional DC EV charger, which will enable solar-powered vehicle-to-home (V2H) and vehicle-to-grid (V2G) functionalities.

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Coherent introduces new fibre lasers for EV battery manufacture

Coherent has introduced a range of adjustable ring mode (ARM) lasers, part of the HighLight FL ARM series, which are designed to enhance the control of the welding process over large working areas. Target applications are those that are common in battery manufacturing for EVs...

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Volvo Penta and FTMH announce range of e-forklifts

Volvo Penta and FTMH have expanded their partnership to include the development of electric forklifts. The companies will develop a range of e-forklifts of up to 52 t. The 26 t capacity FTF 26-12, which currently uses a Volvo Penta D8 engine, will be the first to be electrified as the FTF 26-12 EL.

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GaN switch for 400 V powertrains

Power Integrations has developed a 900 V flyback switching chip with a gallium nitride transistor for more efficient 400 V powertrain designs (writes Nick Flaherty). The InnoSwitch3-AQ uses the company’s proprietary PowiGaN transistor to...

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Electrogenic reveals customer Jaguar E-Type with drop-in EV kit

EV company Electrogenic has revealed the first customer Jaguar E-Type (or XK-E) fitted with one of its plug-and-play, ‘drop-in’ EV conversion kits. The package, which is available worldwide through Electrogenic’s partner...

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Henkel launches a new injectable thermally conductive adhesive for EV battery systems

As a global leader in automotive adhesives, sealants, thermal materials and functional coatings, Henkel Adhesive Technologies is dedicated to help solve the challenges of OEMs and battery manufacturers to accelerate the transition toward zero-emission...

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Bostik and Polytec PT launch new thermal conductive adhesives

Bostik and Polytec PT are launching a new range of thermal conductive adhesives (TCAs) for thermal management in the latest cell-to-pack battery designs for e-mobility solutions...

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Technical Services joins hydrogen fuel cell vehicle project

Technical Services (UK) has been announced as an approved partner of Hyer Power, a project led by hydrogen commercial vehicle conversion company ULEMCo to develop a hydrogen fuel cell (FC) range extender...

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Modular PXI-based BMS tester

Pickering Interfaces has developed a modular test system for battery management systems. The system is based around the PXI standard, and combines a range of modules for fault...

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Ionic Mineral Technologies unveils nano-silicon product for lithium-ion cell manufacturers

Ionic Mineral Technologies (Ionic MT) has launched its Generation 1 Ionisil nano-silicon product for lithium-ion cell manufacturers. It is designed as a drop-in solution for batteries that need high energy density and fast charging...

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Eaton offers sealed high-power lock box connectors

Intelligent power management company Eaton has announced that its eMobility business is now offering specialised high-power lock box...

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Verge Motorcycles launches limited-edition electric superbike

Formula One legend and two-times World Champion Mika Hakkinen has designed the signature model of a new electric superbike in collaboration with Verge Motorcycles. Only 100 models will be produced. The bike has a range of 350 km and a charging time...

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Henkel discusses developments in battery materials

As with most areas of engineering, advanced materials are essential to achieving the energy density, power density, safety and reliability goals for EV battery systems, as well as sustainability-related targets in repair, reuse, repurposing and – collectively known as re-X...

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TI aims to maximise EV driving range with SiC gate driver

Texas Instruments (TI) has debuted an integrated, functional safety-compliant, isolated gate driver it says enables engineers to design more efficient traction inverters and maximise EV driving range...

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Scania completes first charging test with pilot megawatt charging system from ABB E-mobility

Scania has successfully installed and tested a pilot megawatt charging system (MCS) from ABB E-mobility. The technology is said to cut the charging time for heavy-duty vehicles by half...

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LIQUI MOLY develops liquid thermal manager for electric car batteries

LIQUI MOLY develops liquid thermal manager for electric car batteries The automotive chemical specialist is expanding its range for all-electric vehicles with Battery Coolant EV 200 Special drives require special solutions. This is definitely the case with all...

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LEVC launches global EV technology

LEVC (London Electric Vehicle Company) has unveiled its new EV platform, the Space Oriented Architecture (SOA). Co-developed with Geely Holding Group, the SOA is designed to maximise interior space, offering multiple seating and load-carrying configurations. It can support a range of new platforms, from passenger-carrying ...

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REE Automotive unveils P7-C chassis cab

Automotive technology company and EV platforms provider REE Automotive has unveiled the P7-C, a Class 4 chassis cab design built on REE’s P7 modular electric platform. The P7 is aimed at vehicle classes 3-5, and as well as the P7-C, the P7 line-up includes the P7-B box truck and the P7-S stripped chassis. The line-up […]

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Biffa and Lunaz to upcycle and electrify refuse truck fleet

Sustainable waste management company Biffa and vehicle electrification and upcycling business Lunaz are teaming up to replace Biffa’s refuse truck diesel engines with electric motors.

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Fast charging by crystal seedling

Engineers at the University of California San Diego have developed a high-capacity lithium metal battery that can charge in as little as an hour (writes Nick Flaherty). The fast charging is enabled by using lithium metal crystals that can be seeded, and grown quickly and uniformly on a substrate that is different from the traditional […]

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ZF unveils air compressor for fuel cells and announces partnership with Liebherr

ZF has announced a new compressor that pushes air into fuel cells (FCs) for commercial vehicles. It has also announced an exclusive development agreement with

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SiC films could outstrip diamond

Researchers in Japan have shown that the thermal conductivity of thin films of cubic 3C-silicon carbide can be higher than diamond. The team, led by Associate Professor Jianbo Liang and Professor Naoteru Shigekawa at the Osaka Metropolitan University

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Cupra premieres 100% electric SUV and virtual sportscar

Cupra has unveiled its first all-electric SUV coupe, the Tavascan, to be launched in 2024. The Tavascan is based on the Volkswagen Group’s MEB platform, and

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CAKE launches the new IPM e-bike motor

Swedish company CAKE, which makes electric motorcycles, has introduced a new electric IPM motor, the Jante. Featuring an aircraft-grade aluminium

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WAE launches mass-market battery intelligence software

WAE Technologies (WAE) has launched a battery intelligence software package called Elysia, which is designed to improve the life, safety, usable energy, power and rapid charging times of any battery system. It is the first mass-market software offering from WAE, and features embedded and cloud-based products to provide the ability to manage, optimise and enhance […]

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WEVC debuts eCV1 electric van

Low-to-medium volume EV manufacturer Watt Electric Vehicle Company (WEVC) has unveiled its eCV1 light electric van. Following the signing of an MoU between WEVC and electric commercial vehicle specialist Etrux

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Major advance for fast charger

A German project has developed a fast-charger design that can provide 400 km of range for an EV in only 15 minutes (writes Nick Flaherty). The project, called “Direct Superfast charging for the Electric vehicle”...

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ViGem unveils new data logger

Measurement technology company ViGem has extended its CCA 9010 series of data loggers with the launch of its CCA 9010-50BE test bench system. It has been designed to enable the validation of ECUs and...

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Kia starts building facility for electric purpose-built vehicle production

Kia has broken ground in preparation for its dedicated plant for producing battery-electric purpose-built vehicles (PBVs).

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Schaffner’s new EMC solution for residential EV charging stations

EMC systems developer Schaffner has announced a new series of RF chokes, which it says allow designers of residential EV charging stations to cut the cost

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Hyundai puts the Ioniq 5 through its sub-zero paces

Hyundai Motor Company has shared details about the winter testing of its Ioniq 5 N at the Hyundai Mobis proving ground in Arjeplog in Sweden.

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Henkel explains its battery fire-resistant coatings process

Whether EVs are more likely to catch fire than IC-engined vehicles is uncertain, as small sample sizes make reliable statistical comparisons difficult

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Hydrogen Vehicle Systems gears up to launch goods truck

Hydrogen-powered commercial vehicle manufacturer Hydrogen Vehicle Systems (HVS) has confirmed that its zero-emissions hydrogen-electric heavy goods vehicle

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All-in-one unit for heavy-duty EVs

Bel Fuse has developed a 20 kW power conversion unit for heavy-duty EV designs (writes Nick Flaherty). The BCV200-700-8 combines a 15 kW bidirectional inverter-charger, a 4 kW 12 V

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Electric Renault 5 prototypes begin testing

Renault has announced it is testing the future electric Renault 5 using nine prototypes. Known as mules, their platform, powertrain and battery are technically the

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Farasis unveils concept for preventing thermal runaway

Lithium-ion pouch cells supplier Farasis Energy has developed a module design concept to prevent thermal runaway in its latest generation of pouch cells,

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Xing Mobility and Nordic Booster supply solutions to the industrial EV market

Xing Mobility, which provides immersion cooling battery

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WiTricity and ABT e-Line to bring wireless charging to Europe’s streets

ABT e-Line and WiTricity have announced plans to

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Premo unveils triple low-loss LLC onboard charger

Premo has developed a triple 3.6 kW LLC set (suited for 400 V Input) with a transformer and resonance inductor designed for onboard chargers capable of handling up

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GaN chips edge into SiC space

VisIC Technologies has successfully tested its 2.2 mΩ 650 V half-bridge power module with a mainstream permanent magnet synchronous motor (writes Nick Flaherty). The module consists of

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Cissoid teams up with Silicon Mobility on SiC inverter

Cissoid and Silicon Mobility have announced a partnership to deliver a complete and modular SiC inverter reference design supporting electric motor

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Volvo Penta and Gradall collaborate on electric excavator concept

Gradall has unveiled an electrified concept model of its

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Toyota to supply hydrogen fuel cells to truck company Hyliko

Start-up business Hyliko is planning to integrate Toyota’s second-generation hydrogen fuel cell

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Universal Hydrogen completes first flight of fuel cell regional airliner

Universal Hydrogen has flown a 40-passenger regional

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BYD ATTO 3 debuts in the UK

The all-electric BYD ATTO 3 C-Segment SUV is now available to order in the UK. There are three variants in the range – Active, Comfort and Design. The ATTO 3 is the first SUV to be built on BYD’s e-Platform 3.0, which

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Allegro Microsystems announces ASIL C current sensor for EVs

Allegro Microsystems, a provider of power and sensing solutions for motion control, has released samples of its ACS37601, an ASIL C safety-rated field current sensor

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Hyundai announces second-generation KONA

Hyundai has unveiled its all-new KONA, which is aimed at the B-SUV segment. Customers can choose from EV (standard or long range), hybrid EV and IC engine

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Audi launches limited-run mountain bike

Audi is expanding its range of e-mobility products with the launch of a limited-run electric mountain bike. Based around an enduro frame made from lightweight

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Xerotech and Innolith to bring non-flammable batteries to market

Xerotech, a battery pack provider for heavy-duty non-road mobile machinery, is teaming up with battery cell developer Innolith to launch what they say are the

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All-new Prius PHEV about to go on sale

oyota has announced that it will begin sales of its all-new Prius PHEV models, offered as the Z grade, on March 15. They have a maximum system output of 164

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Airbus discusses role of hybridisation in aviation’s future

Airbus says it believes hybrid-electric power can reduce aircraft CO2 emissions by up to 5%, and by up to 10% for helicopters. It has already flight tested a hybrid-

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AirShaper offers fixed-price options for aero testing

Aerodynamic testing continues to shift away from wind tunnels and into the virtual world of computer models and CFD packages, but barriers to entry remain high

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Equipmake launches motor for harsh environments

Electrification specialist Equipmake has unveiled an ultra-lightweight, power-dense electric motor, designed

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Tevva partners with Ecobat for first-life battery management

Electric truck manufacturer Tevva has entered into a strategic partnership with battery recycling Ecobat for the repair, repurposing and recycling of its lithium-ion

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Taylor and Rocsys partner up on autonomous container charging

Taylor Machine Works, which design and manufactures zero-emissions container handlers, has announced a partnership with Rocsys to offer robotic chargers for the

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Eaton introduces 3-in-1 battery pack vent valve for EVs

Power management company Eaton has announced that its eMobility business has introduced a 3-in-1 battery pack vent valve for EV batteries. The valve

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Magicycle unveils world’s first step-through full suspension e-bike

Magicycle has launched its Magicycle Deer e-bike

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EV achieves 1000 km without stopping to charge

Students from the University of New South Wales (UNSW) have become the first people in the world to

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CT scanner inspects the ‘un-inspectable’

Scientists from the CTLAB at CEITEC (Central European Institute of Technology at Brno University of

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Fraunhofer Institute develops hydrogen-from-ammonia reactor

Researchers at the Fraunhofer Institute for Microengineering and Microsystems have announced ammonia-based systems for a mobile, decentralised

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ZeroAvia tests hydrogen-electric aircraft

ZeroAvia has flown a 19-seat Dornier 228 twin-engine aircraft as a testbed for its full-sized hydrogen fuel cell engine (writes Nick Flaherty). The aircraft was retrofitted

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Farasis Energy Europe joins structural batteries project

Farasis Energy Europe (FEE) is taking part in the PEAk-Bat project, which is funded by the German government, to reduce the development

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New brake components from ZF Aftermarket

ZF Aftermarket is launching three new or revised TRW products for brake repairs, including a copper-free

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Europa hydrogen-powered truck to launch later this year

Zepp.solutions has unveiled more specifications and the name for its new hydrogen fuel cell powered truck, the Europa, which is designed as a zero-emissions

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Lunaz Design unveils world’s rarest upcycled EV

Lunaz Design has unveiled what it says is the rarest classic car ever to be transformed to fully electric power. Its 1961 Bentley S2 Continental is one of only four

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Enhancing hybrid power capacitor safety

Capacitor battery developer Kurt Energy has outlined how it complements the inherent safety of its 18650Y and 21700Y

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KEB Automation uses Yokogawa power analyser to build more efficient motor drives

German automation and motion control specialist KEB

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Marelli wins contract to supply BMS to major EV carmaker

Marelli has been awarded a contract to supply a BMS for the small-to-medium battery EVs of a major global carmaker. Marelli will provide both the hardware and the

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Wolfspeed and ZF announce partnership to develop SiC devices

Wolfspeed and ZF have announced a partnership that

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Dow unveils silicone rubbers for injection moulding

Dow has unveiled a new range of liquid silicone rubbers (LSRs) designed for two-component injection moulding with thermoplastic substrates including polybutylene

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Quantum leap for cell current tests

Researchers in Japan have used a quantum sensor with a wide dynamic range and high sensitivity to measure the current in a battery pack more accurately than traditional techniques (writes Nick Flaherty). The team

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Emulator hands power back to grid

Keysight Technologies has updated its regenerative DC emulator to support higher power up to 270 kW for powertrain testing (writes Nick Flaherty). The Scienlab

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Far-UK shows carbon fibre skateboard EV chassis

UK composite construction specialist Far-UK is developing a primarily carbon fibre skateboard chassis concept that can be applied to light vehicles with

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Rugged packs from standard module

Proventia has launched a modular rugged battery pack for off-road construction equipment (writes Nick Flaherty). The ePRO500+ platform uses lithium titanate

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Researchers gain insights into improving lithium-ion cells

A team of scientists from the US, Canada and Germany (led by researchers at Texas A&M University, TAMU) have combined novel imaging techniques and large

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Motor mode programming made easy

Synchronising motors and controllers is a key aspect of EV powertrain development, and Friwo’s electrification kits come with an algorithm that automates that

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Three-wheeler given new design

White Motorcycle Concepts (WMC) has started production of a new design of its electric-hybrid three-wheel scooter (writes Nick Flaherty). The WMC300FR uses a patented Venturi duct technology added to a

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Polymers confer safety and comfort

Ascend Performance Materials has developed two materials for EVs that improve safety and passenger comfort (writes Nick Flaherty). The Starflam X

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High-power modular EV cell cycler

NI has launched a battery cycler that supports testing packs with a power of up to 150 kW (writes Nick Flaherty). The High Power System (HPS) 17000, NI’s highest voltage cycler at 1500 V,

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Thermal elastics extend cell lifetimes

Dow has launched a range of thermal elastic high-bonding adhesives to improve safety, sustainability and integrated assembly of EV battery packs (writes Nick

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Hall effect sensors include simulator

Melexis has launched two types of Hall current sensor for e-mobility power systems, along with an online simulation tool (writes Nick Flaherty). The MLX91230

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Cloud twin helps to extend EV range

NXP has connected a battery management system (BMS) through its cloud computing gateway to create a digital twin of a vehicle battery (writes Nick Flaherty).

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Toyota to develop hydrogen-powered Hilux in the UK

Toyota has won a £11.3 million grant to produce a hydrogen version of its Hilux pick-up truck in the UK (writes Nick Flaherty). Toyota Motors UK (TMUK) is working with Ricardo, ETL, D2H and Thatcham Research on the project, which will use of the 650 V second-generation fuel cell developed for Toyota’s Mirai, launched in […]

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Liqui Moly discusses its new EV-specific brake fluid

Liqui Moly has developed a brake fluid formulated for the unique requirements of EVs (writes Rory Jackson). While it might be assumed that the brake system at the wheels is one component that remains the same between EVs and IC engine-powered vehicles, the only significant similarity is that the brake fluid needs to be changed […]

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Software predicts future cell health

A machine learning algorithm could help reduce charging times and prolong battery life in EVs by predicting how different driving patterns affect battery performance (writes Nick Flaherty). Researchers from the University of Cambridge in the UK developed a non-invasive impedance-based approach to get accurate data on the state of health (SOH) of a battery. The […]

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EV battery supply chain problems not all doom and gloom

Although global demand for new EVs is strong, the whole industry is still being disrupted by factors including the effect of the Covid-19 pandemic on supply chains, sanctions in response to the war in Ukraine, and inflation (writes Peter Donaldson). At September’s Battery Show in Novi, Michigan, LMC Automotive’s senior manager, powertrain forecasting, Kevin Riddell, […]

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Modified anodes boost cell cycling

Researchers in South Korea have developed a new method of modifying conventional anodes to improve the cycling performance of a battery cell (writes Nick Flaherty). The team, at the Gwangju Institute of Science and Technology, used a layer of graphene oxide – a single atomic layer of carbon – on a silicon anode to prevent […]

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Bespoke chips for drivetrains

STMicroelectronics has launched a family of microcontroller chips designed specifically for electrified drivetrains (writes Nick Flaherty). The Stellar P microcontrollers are automotive qualified and combine the CAN-XL in-car comms standard to handle the demand for more real-time data with actuation functions. The controllers are built on a 28 nm fully depleted silicon-on-insulator (FD SOI) process. […]

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Solid-state cell with 3-minute charge

Researchers in the US have developed a solid-state lithium metal battery for use in future EVs that would fully charge in as little as 3 minutes (writes Nick Flaherty). The technology, which has a lifetime of 10,000 cycles, has been licensed by Harvard University to Adden Energy to scale up to pouch and then prismatic […]

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Cummins develops fuel cell e-turbocharger

Pumping air into an engine so that more fuel can be burned is a long-established means of persuading the engine to provide more power and, in the case of turbocharging, greater fuel efficiency (writes Peter Donaldson). These days, the same technique is being applied to fuel cells and for the same reasons. Cummins, for example, […]

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Equipmake’s ZED system for buses set to enter service

Developing heavy-duty powertrains for integrating into electric passenger buses is fundamentally different from other EV applications, owing to their unique drive cycles and weight-carrying considerations, and their dramatically different HVAC requirements (writes Rory Jackson). Unlike other EVs, an electric bus can expend as much energy on heating and cooling its cabin interior as it does […]

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Ammonia heralds smell of success

Amogy in the US has demonstrated its ammonia-powered technology in a heavy-duty electric vehicle for the first time (writes Nick Flaherty). The 100 kW tractor marks a 20-fold increase in the performance of the technology over the past year. It uses ammonia (NH3) with a fuel cell rather than hydrogen to provide access to a […]

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48 V bidirectional charger for hybrids

EPC has developed a reference design called the EPC9165 for a 2 kW bidirectional charger in 48 V hybrid vehicles using GaN transistors (writes Nick Flaherty). Mild hybrids running on 48 V require a 48 to 12 V bidirectional converter, with power ranging from 1.5 to 6 kW. The EPC9165’s design uses a synchronous buck/boost […]

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Tackling EV tyre particulates

The most supportable claim by EVs to environmental friendliness is that they lead to cleaner air in towns and cities because they emit no combustion products (writes Peter Donaldson). The fly in that ointment is particles from tyre wear, of which EVs tend to generate more because they are heavier than comparable IC-engined vehicles and […]

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Cool approach to efficient air liners

GKN Aerospace has been working on cryogenic technology to boost the efficiency of hydrogen fuel cells and electric motors for aircraft (writes Nick Flaherty). The ‘hyperconducting’ systems proposed by the company use the liquid hydrogen stored in the aircraft as fuel as a heat sink, cooling the electrical conductors to temperatures below -200 ºC to […]

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From black mass to high-purity cobalt

Aqua Metals has demonstrated a key step in using recycled elements in the production of lithium-ion cells for EVs (writes Nick Flaherty). The company, based in Nevada, has successfully plated high-purity cobalt and produced manganese dioxide from lithium-ion battery black mass. Black mass is the result of the recycling process of lithium ion battery cells […]

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BMW opts into series hydrogen

BMW has started series production of electric powertrains based on hydrogen fuel cells, in a major step forward for the technology (writes Nick Flaherty). Previous production has been for prototype and test vehicles, using fuel cell technology developed in-house. BMW’s hydrogen powertrain will now be used in the company’s iX5 Hydrogen, which will be built […]

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Less neodymium, more cerium

Engineers at the Korea Institute of Materials Science have developed a process for producing high-performance and cost-effective magnets for high-speed electric motors using cerium to reduce the amount of neodymium (writes Nick Flaherty). Cerium is an abundant rare earth element, while neodymium is in increasingly short supply, driving up prices. The process can reduce the […]

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Tunnel devices come into the light

Murata has launched its first series of high-performance coreless current sensors using tunnel magneto-resistive (TMR) elements (writes Nick Flaherty). The MRD series of open-loop current sensors integrates high-performance TMR elements. These use a magneto-resistive effect that occurs in a magnetic tunnel junction composed of two ferromagnets separated by a thin insulator. The insulator, typically a […]

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Technical Services discusses benefits of high-voltage thermal management

There are big, system-level energy savings to be made in thermal management by switching high-power components such as pumps and fans to higher voltages (writes Peter Donaldson).   Technical Services should know. It is the UK-based European technical partner of US electric pump and fan manufacturer EMP, handling application engineering for OEMs. Its sales and […]

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BorgWarner’s plans for high-voltage commercial vehicle power systems

Total cost of ownership, long service life and packaging efficiency that frees mass and volume for cargo and passengers are essential requirements for all commercial vehicles (CVs) – and meeting all those needs is a challenge as the sector transitions to electric power, according to Harry Husted, BorgWarner’s vice-president and CTO (writes Peter Donaldson). Speaking […]

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Flextem’s PTC heating films for batteries

Heating is as important as cooling in the thermal management of battery packs, since lithium-ion batteries need to be held within the temperature range specified by the cell manufacturer if they are to operate safely and efficiently, and achieve their maximum service life (writes Peter Donaldson). Efficient, self-regulating positive temperature coefficient (PTC) heaters constitute an […]

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Reference design aimed at e-bikes

Efficient Power Conversion (EPC) has developed an inverter reference design based around an integrated gallium nitride (GaN) chip that reduces the size of powertrains in electric bikes (writes Nick Flaherty). The design, for a 1.5 kW three phase brushless DC motor drive inverter, uses the EPC23101 eGaN chip. This has an embedded gate driver function […]

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RAMPF Group’s battery production materials and processing technologies

To be competitive in global markets, ultra-fast production processes are essential. That is also true for the manufacture of batteries, for which RAMPF Group has developed polymers for sealing, casting and thermal management, as well as dispensing and automation systems. RAMPF uses epoxy, silicone and polyurethane polymers for sealing, casting and thermal management solutions for […]

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BorgWarner to start production of Akasol CYC battery modules

Cylindrical cells and central liquid cooling are key architectural characteristics of the new “ultra-high-energy” Akasystem AKM CYC module technology from BorgWarner, which acquired its developer Akasol in February (writes Peter Donaldson). The system is a scalable set of battery modules designed to be built up into packs for heavy vehicles including buses and trucks, along […]

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Gate driver designs for heavy EVs

Power Integrations (PI) has developed two versions of its gate driver board that is suitable for powertrain designs in heavy equipment such as trucks, buses, and agricultural and construction equipment (writes Nick Flaherty). The Scale EV gate driver boards are designed to fit on top of Infineon’s EconoDual half-bridge modules in the same footprint. The […]

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DAFO Vehicle battery fire protection system

In a thermal runaway, a lithium-ion battery typically releases oxygen from the cathode and volatile hydrocarbons from the electrolyte, generating both oxidiser and fuel to sustain a fire from purely internal sources (writes Peter Donaldson). Reliable detection and early intervention are therefore critical for preventing the worst consequences of battery thermal incidents – fire and […]

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Going large offers longer range

Advanced Cell Engineering (ACE) has filed a patent application for a very large format (VLF) battery cell (writes Nick Flaherty). The filing, in the U,S is part of its Project Magnus to develop a highly efficient, 1 m cell-to-pack prismatic cell. It is ACE’s fourth patent application in the past 6 months. Rather than using thousands […]

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System-level approach to NVH models

Complex interactions between electric powertrain components provide significant challenges in accurately predicting the noise, vibration and harshness (NVH) performance of a design when using high level system-level models (writes Nick Flaherty). The models can help reduce the cost and development time, but the underlying interaction of the component-level simulations needs to be understood to achieve […]

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Super-fast silicon cell charging

BATTERY CHARGING Enovix has demonstrated 5 minute charging of its prototype silicon battery cells for EVs (writes Nick Flaherty). Tests on the 0.27 Ah cells demonstrate charging from 0 to 80% charge in 5.2 minutes, and achieve a greater than 98% charge capacity in under 10 minutes. The cell uses a 100% silicon anode with […]

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Safe AI for batteries

While we are growing used to artificially intelligent software in smartphones, for example, if  AI and machine learning are to benefit EV applications such as controlling batteries, inverters and motors, the software must meet all the safety, security and quality standards that apply to serial production vehicles in the automotive industry. This is the mission […]

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Autocraft battery re-manufacturing

With 40 years of experience re-manufacturing internal combustion engines and transmissions for automotive OEMs, Autocraft Solutions Group has turned its attention to EVs in recent years and has developed both fixed and mobile battery re-manufacturing systems to meet a growing need, as CTO Simon Warburton explains to Peter Donaldson. That need is to match battery […]

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Rover will offer mission flexibility

Venturi Astrolab has developed an electric lunar rover with a flexible payload architecture to support a range of regular missions for astronauts (writes Nick Flaherty). The company plans to offer a fleet of these Flexible Logistics and Exploration (FLEX) rovers to support a sustained human presence on the Moon and Mars. The FLEX’s four-wheel crab […]

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Novus urban e-bike nears production

With an initial price of around €30,000, the Novus e-bike is aimed at people who want to make a statement about their embrace of ‘green’ technology rather than those who simply need practical urban transport (writes Peter Donaldson). However, the 30 kW, 400 Nm, 85 kg, all-composite two-wheeler, which was on display at the Battery […]

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BorgWarner installs first Iperion 120 fast chargers

In-field analysis, along with a deep knowledge of the power electronics components, enabled BorgWarner Systems to get full power in high ambient temperatures from its new Iperion 120 rapid charger during the initial installation programme in northern Italy, where the first units are in operation (writes Peter Donaldson). “In the northern part of Italy the […]

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Elaphe’s approach to in-wheel motor development

Specialising in complete in-wheel electric powertrains, Elaphe’s development roots go back to the late 1980s (writes Peter Donaldson). However, the company was only officially founded 16 years ago, to pioneer in-wheel motors and multiple-wheel drive control systems, which it has evolved into a complete technology platform. “One of the most important things for us in […]

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Wax works well for conducting heat

Researchers in the US and China have developed an economic but efficient battery thermal management strategy using paraffin wax (writes Nick Flaherty). The 3D, interconnected, thermally conductive boron nitride network greatly improves thermal conductivity compared to random distribution. “We designed a 3D network of boron nitride, and systematically studied its effect on the thermal management […]

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Protecting electric ships with rapid DC switching

Potentially critical faults in the high-power DC powertrains increasingly found in ships, particularly ferries, must be isolated as quickly as possible to minimise damage and allow the rest of the system to continue operating as normal (writes Peter Donaldson). Key to this is the application of solid-state power electronics in the form of switches based […]

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Lotus gives update on LEVA platform

Lotus has openly said that its latest sportscar, the Emira, will be its last mainstream model with an IC engine (writes Peter Donaldson). Its next-generation two-seater will be based on the Lightweight Electric Vehicle Architecture (LEVA), on which Lotus is working with initial funding from industry body the Advanced Propulsion Centre, in partnership with casting […]

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SABIC cube cells pack more energy

Engineers at materials firm SABIC have patented a design for a battery pack using cuboidal cells (writes Nick Flaherty). The cells are inserted into a structural backbone made from a thermoplastic, and could increase battery pack energy density by 20% or more, with 10% more cells compared to a pack using cylindrical cells , along with […]

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AGRO explains importance of EMC-shielded cable glands

Like most small parts in complex vehicle systems, the glands that support, seal and protect the interfaces between HV cables and the components they link rarely receive the attention that the critical nature of the functions they fulfil perhaps ought to command (writes Peter Donaldson). AGRO’s EVolution EMC cable glands are a case in point, […]

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Design unveiled for 800V inverter from Texas Instruments

Texas Instruments has developed a reference design for an 800 V, 11 kW three-level, three-phase inverter using gallium nitride (writes Nick Flaherty). The inverter uses a 6.6 kW active neutral-point clamped (ANPC) inverter design with a 600 V LMG3422R030 GaN FET. This enables a switching frequency of 100 kHz to reduce the size of the […]

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Ferries to launch with fast charging

Five electric ferries are set to operate around the clock across the North Sea Canal in Amsterdam using a fast charging system developed by ABB (writes Nick Flaherty). They will replace a diesel-powered fleet that dates back to the 1930s, and will be used on three busy North Sea Canal routes that transport more than […]

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Components keep their cool in 3D

A feasibility study has examined the use of over-moulding to create 3D electronic components with high thermal conductivity (writes Nick Flaherty). The project, at Sobaplast in Germany, uses the Keratherm MT 103 and MT 320 injection moulding materials from Kerafol on circuit board samples at temperatures that did not compromise the components on the board […]

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Onboard charger cuts it both ways

Vicor has shown a modular approach for a ‘virtual battery’ that can tackle issues with DC fast charging of EVs (writes Nick Flaherty). Many existing DC fast chargers work with 400 V packs but not the 800V versions. In 2020, there were around 400,000 publicly accessible DC fast chargers around the world, but only 2% […]

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Module aimed at 900V powertrains

NXP Semiconductors is working with Hitachi on a power module using 1200 V SiC transistors (writes Nick Flaherty). The collaboration combines NXP’s GD3160 isolated gate driver and Hitachi Energy’s RoadPak SiC half-bridge power modules for faster development of efficient, reliable and functionally safe EV powertrains using 900V battery packs.The RoadPak uses 1200 V SiC MOSFETs, […]

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Sono Motors sets sights on whole-vehicle PV panels

Sono Motors, developer of the Sion solar-powered car, is working on integrating solar cells into all of its five-door, five-seat family hatchback’s outer body panels (writes Peter Donaldson). The Sion is a BEV with a 54 kWh battery that the company expects to provide a range of 305 km on a full charge, with the […]

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Holding electronics together under high voltages and temperatures

While EVs may have much in common with consumer electronics, the combination of high voltages and powers, and the safety-critical nature of many of their systems, is providing some major headaches for printed circuit board assembly (PCBA) contractors and electronics manufacturing services (EMS) providers – headaches that vehicle OEMs won’t be able to cure with […]

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Efficiency record for EV solar cell

Toshiba has developed a transparent solar cell that can be used to boost the charging of EVs (writes Nick Flaherty). The cell uses copper oxide and has an efficiency of 8.4%, the world’s highest level for such as cell. It would sit on top of a flexible silicon solar cell on the roof or trunk […]

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Manual EV gearbox simulator

Toyota has filed a series of patents in the US for simulating a manual gearbox in an EV (writes Nick Flaherty). The set of eight patents would have an impact on the design of the central motor controller, influencing the torque of the motor based on the operation of the accelerator and a ‘pseudo-clutch’ pedal. […]

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Airbus combines electric aircraft designs for air mobility initiative

Airbus is combining its two short-range electric aircraft designs – the rotor-based Vahana and the fixed-wing CityAirbus NextGen concept – for a collaboration in Germany (writes Nick Flaherty). “The first is for a long hover times, for example for rescue operations, while the Vahana is for longer flights, for example from Nuremberg to Munich,” says […]

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Maritime pack protection system

KULR has developed a passive propagation resistant (PPR) system to protect maritime battery packs against the risk of fire (writes Nick Flaherty). The US Coast Guard is launching new safety requirements for passenger vessels, and the PPR developed by KULR provides additional battery safety options for the cargo ships, fishing trawlers and cruise liners. A […]

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EV code looks to set station standard

Pionix in Germany has developed an open source software stack to address the fragmentation of EV charging infrastructure (writes Nick Flaherty). The EVerest software is a minimal Linux system that can run on any device, from chargers using a home socket to public DC charging. It uses a modular, customisable software stack that abstracts the […]

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WAVE hello to wireless charging for commercial EVs

Aaron Gillmore, the CEO at wireless inductive charging system developer WAVE, believes that the market has reached a take-off point in commercial medium- and heavy-duty commercial EV fleets (writes Peter Donaldson).  “The technology is here now,” he says. “Over the last 10 years the WAVE team has put in a lot of work to design […]

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Fast charge rate beats US targets

Amprius Technologies has demonstrated a charging rate of 6 minutes to 80% from 0% state of charge for its silicon-based batteries (writes Nick Flaherty). This exceeds the targets for 2025 set by the US government for charging a battery cell to 80% in less than 15 minutes.  Using silicon nanowires avoids the problems of the […]

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Wireless BMS simplifies pack design

Visteon has launched a wireless BMS and added smart junction box technology to simplify battery pack designs (writes Nick Flaherty). The company has been involved in BMS development since the earliest days of EV production when it supported the 1998 Ford Ranger EV. The wireless BMS uses chips from Analog Devices to eliminate the traditional […]

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Breakthrough for lithium-sulphur batteries

A cell technology holding 900 Wh/kg – three times the energy density of state-of-the-art lithium-ion battery chemistries – that is safer and cheaper thanks to the use of abundant and easily accessible sulphur for the cathode in place of nickel manganese cobalt oxide (NMC) is an exciting prospect (writes Peter Donaldson). Batteries that use sulphur […]

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Lithium-air pack beats lithium-ion

Researchers in Japan have developed a lithium-air battery that has a far higher energy density than current lithium-ion batteries (writes Nick Flaherty). Lithium-air batteries have the potential to be the ultimate rechargeable packs, as they are lightweight and have high capacity, with theoretical energy densities of 3150 Wh/kg – several times that of the lithium-ion […]

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Going electric gives classic off-roader new abilities

Examples of classic vehicles converted to electric power abound, but SC Innovation’s reworking of the rugged skid-steered 6 x 6 All-Terrain Mobility Platform (ATMP) is remarkable because, rather than adding a high-tech twist to an exercise in nostalgia, it brings new capabilities to a machine that has filled niches in military, agricultural and other utility […]

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Conversion service for classic mini

Following a one-off project in 2018, BMW is now offering a service to convert the classic petrol-driven Mini to electric propulsion (writes Nick Flaherty). The original was launched in 1959, created during an oil crisis and based on the idea of saving fuel and transporting four occupants and their luggage in the smallest possible footprint. […]

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HV SiC MOSFET switch ships for EVs

Power Integrations (PI) has launched its first high-voltage switch chips for automotive battery packs that use a SiC MOSFET (writes Nick Flaherty). The package for the InnoSwitch3-AQ integrates a 1700 V SiC MOSFET for 800 and 1000 V battery packs where a 1200 V device would not be able to handle the peak voltage that […]

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OMSI announces move into heavy-duty applications

With a 70-year history in manufacturing gearboxes, axles and power take-off (PTO) units for trucks, special-purpose machines and the railway industry, Italy’s OMSI Trasmissioni is now targeting heavy-duty e-mobility applications with a new range of hybrid and electric drives that exploit modern electric motors with high power densities (writes Peter Donaldson). “We can work with […]

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NXP intelligent gate drivers for traction inverters

Long-established IC-engined vehicle OEMs and new EV specialists are competing to get EVs to market rapidly while being faced with rising costs and the desire to maintain control of the intellectual property embodied in their vehicles (writes Peter Donaldson). Under this pressure, many are responding by building up their abilities to design, develop and manufacture […]

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Separator and current collector protect cells from shorts

Soteria Battery Innovation Group, together with a consortium of more than 110 organisations, is making available new separator and current collector technologies that protect battery cells from the effects of internal short-circuits (writes Peter Donaldson). The consortium members include NASA, Mercedes-Benz, Lenovo, DuPont, Bosch and Motorola. As European consortium director Dr Juergen Kellner explains, “We […]

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High-speed marine motor addresses critical need

Rapid acceleration may not be the first thing that comes to mind when considering marine vehicles that serve the offshore industries, but it is important because it increases their operational limits, enabling them to be deployed for longer in higher sea states (writes Peter Donaldson). That is one of the key selling points of Walker […]

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Making the cases for battery transport

As the EV industry grows, the logistics of moving major components – particularly batteries – between facilities has to be closely considered, argues Olivier Saada, business development manager for containers at battery transport packaging specialist Corplex (writes Peter Donaldson). EV batteries are considered dangerous goods and fragile items, and the company makes cases that are […]

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Wireless charging by magnetic induction

Andy Daga, founder, president and CEO of Momentum Dynamics, wants to make charging EVs easier than refuelling IC-engine vehicles while enabling practically unlimited range in day-to-day driving, at least in urban and suburban environments (writes Peter Donaldson). The company is now rolling out its wireless charging system based on magnetic induction technology for large vehicles […]

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Cool SiC inverters move

Researchers at the US National Renewable Energy Laboratory (NREL) have been working with heavy-duty equipment maker John Deere on a new thermal management system for SiC inverters (writes Nick Flaherty). Equipment such as trucks and construction machines account for 39% of greenhouse gas emissions in the transportation sector, so there has been a focus on […]

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Webasto swappable batteries power Staad electrified excavators

With many European cities now insisting that machinery such as excavators used on construction sites must not produce harmful emissions, the pressure on the industry to electrify them is growing (writes Peter Donaldson). In 2020, Staad, the Dutch importer of Doosan machinery, formed its Electric Construction Equipment (ECE) division to convert excavators and now offers […]

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Meeting the challenges of developing e-VTOL air taxis

AutoFlight’s Prosperity I, a Chinese-designed e-VTOL air taxi sized to accommodate a pilot and three passengers, is intended to meet the rigorous safety standards that apply to transport-category aircraft including the largest airliners, and the company is aiming for certification and service entry in 2025 (writes Peter Donaldson). Invited by electric aviation pioneer and AutoFlight’s […]

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A case of plastic over aluminium

Containing thermal runaway, protecting EV occupants from fire and saving weight are all drivers for the application of new materials to batteries, and the battery case is a prime target for replacing aluminium alloy with plastics (writes Peter Donaldson). Multi-industry plastics specialist SABIC has recently re-engineered existing EV battery cases in two proof-of-concept exercises that […]

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Fast charge ahead for BMW vehicles

Sprint Power is leading the development of an 800 V fast-charging system for BMW (writes Nick Flaherty).   The Celeritas project is a £9.7 million effort to develop fast-charging cells and battery packs for battery EVs and fuel cell hybrid EVs. As well as BMW, its members include the UK’s Advanced Propulsion Centre, BP, AMTE […]

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Dual-component power converter

Premo has developed an 11 kW power converter using its patented technology that integrates multiple magnetic components (writes Nick Flaherty). The 3DP-11KWHVHV combines a full-bridge 150 µH LLC resonant transformer and 25 µH resonant choke in a single unit. This cuts the volume of the converter by up to half, and can reduce the amount of […]

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Lithium-metal cell packs a punch

With a specific energy of 400 Wh/kg and an energy density of between 700 and 810 Wh/litre, Sion Power’s Licerion-EV rechargeable lithium-metal cells are attracting great interest from EV developers, and the company is in discussion with multiple OEMs to further the development of the technology (writes Peter Donaldson).    The company’s senior applications engineer […]

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Inverter integration cuts size, weight

Texas Instruments has integrated a transformer into a gate driver to enable distributed switch architectures for inverters (writes Nick Flaherty). The UCC14240-Q1 isolated DC-DC bias supply module integrates the transformer and components with 3.5 mm-high planar magnetics to reduce the size, height and weight of a distributed power system in an inverter. The integration of […]

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Schaltbau launches arc-quenching high-current DC contactors

Switching large direct currents safely and responsively is a critical task in EV drive systems, requiring electromagnetically controlled contactors that extinguish the unwanted arcs that inevitably form between the main contacts when they open (writes Peter Donaldson). Drawing on almost a century’s experience in the railway industry, German company Schaltbau is addressing this issue by […]

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Feinmetall launches high-current contacts for battery testing and production

As currents produced by EV batteries get higher, the demands placed on the contacts in the systems used to check cell, module and general battery performance in testing and production are also increasing. High-performance contact probes are therefore growing in importance (writes Peter Donaldson). To that end, contacts manufacturer Feinmetall has launched a family of […]

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Inverter sintering set to boost range

MacDermid Alpha Electronics Solutions is working with STMicroelectronics on improved sinter technology for EV inverter assemblies. The process, known as pressure sintering, can significantly increase vehicle efficiency and range as well as lowering production costs (writes Nick Flaherty). Pressure sintering provides much lower thermal resistance in an inverter, which leads to better power cycling and […]

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Cressall unveils liquid-cooled brake resistors

In electric and hybrid vehicles, regenerative braking is a very effective means of recovering energy by recharging the battery, but sometimes it recovers more energy than the battery can accept (writes Peter Donaldson). This is particularly true for large vehicles such as trucks, buses and off-highway machines on a long run downhill that start with […]

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BorgWarner launches high-altitude charging station

With charging capacity increasingly seen as a limiting factor in the growth of EV markets around the world, BorgWarner Systems has been sharing more details about its new Iperion 120, a 120 kW charging station designed to form the heart of its efforts to create modern charging infrastructures (writes Peter Donaldson).   A key feature […]

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New chapter in the story of cork

Finding a material with several applications in state-of-the-art EV powertrains that literally grows on trees might seem unlikely, but that is exactly what Portuguese company Amorim Cork Composites is offering with cork (writes Peter Donaldson). The raw material is the bark of the cork oak tree (Quercus suber), which in addition to its best-known application […]

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Motor wire is ‘green’

Tau has started shipping prototype environmentally friendly winding wire to the automotive industry. The wire combines minimised partial discharge, high fill factors and improved temperature resistance for high-voltage and frequency optimisation for electric motors.

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Cotes cuts carbon footprint of running dry rooms

Drying rooms are critical to lithium-ion battery manufacture to ensure that the electrodes are prevented from absorbing moisture, which can lead to a reduction in lifespan and even catastrophic failure (writes Peter Donaldson). Running these dry rooms typically takes a lot of energy, mostly to provide hot air. However, Danish company Cotes has developed a much more efficient way it calls Exergic Technology to do this that significantly reduces the battery’s overall carbon footprint. Understanding humidity is key to getting rid of unwanted moisture from air, and warm air holds more water than cold air. Absolute humidity is the amount of water vapour in a given mass of air, and is typically expressed in grams per kilo. Relative humidity, meanwhile, is the amount of water in the air expressed as a percentage of the maximum it can hold at a given temperature. When that percentage exceeds 100, the water begins to condense out.

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Ricardo shows Steel E-Motive Level 5 concept EVs

Keen to show off what the latest generation of advanced high-strength steels can do, WorldAutoSteel, the automotive arm of the World Steel Association, has chosen Ricardo to design an EV family that could be offered in the nascent market for mobility as a service from around 2030 (writes Peter Donaldson). The first two designs created under this Steel E-Motive (SEM) initiative were revealed at the recent Battery Show Europe and Electric & Hybrid Vehicle Technology Expo in Stuttgart, where WorldAutoSteel’s technical director George Coates and Ricardo’s chief engineer for vehicle attributes Neil McGregor outlined the progress with them so far.

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Project tests electric truck for work in the Arctic

Operating EVs in extreme temperatures is a demanding exercise, as lithium-ion batteries generally work best between 15 and 35 C, so a four-week trial conducted throughout February 2021 above the Arctic Circle in Sweden was a severe test of a truck and its charging infrastructure (writes Peter Donaldson). In the test, the battery-powered truck carried loads of 14 t of iron ore sludge over a 280 km round trip in temperatures down to -32 C, says Adam Holmer of power-as-a-service provider Vattenfall. The trial was a cooperative effort between Vattenfall, Volvo Trucks and dealer Wist Last och Buss, charger manufacturer ABB and mining company Kaunis Iron.

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Flat chassis chosen for axial motors

Saiettta has used its AFT140 axial motor for a flat chassis for urban vehicles (writes Nick Flaherty). Mounted on the corners of the chassis, the AFT 140 in-wheel electric motors provide a torque of up to 140 Nm for controllable power at low speeds in urban stop-start journeys. The chassis is a flexible platform that […]

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Device reads LV and HV in one go

A 45 V high-withstand voltage battery monitoring device for automotive designs has implemented a supply voltage-divided output for the first time (writes Nick Flaherty). Dividing battery monitoring between high- and low-voltage sources increases the safety of e-mobility designs, as it allows 12 V batteries to be monitored by the same device that monitors the low […]

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Ground vibration testing of NASA’s X-57 Maxwell electric aircraft

Electric propulsion is spawning aircraft with diverse and novel configurations. The multiple motors, rotors, propellers and fans associated with distributed electric propulsion are shaping many complex and unusual forms in the quest to enhance lift and thrust, and to reduce drag through close aerodynamic coupling with airframes. One of the most important processes in their development is ensuring that they don’t suffer from damaging vibration. To that end, NASA has used equipment from Hottinger Bruel & Kjær (HBK) to collect and process accelerometer data in ground vibration testing (GVT) for its X-57 Maxwell aircraft.

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Silver Power Systems and partners develop ‘world’s most advanced’ battery digital twin

An established concept in other areas of industry, a digital twin is a high-fidelity software model of a real system to which it is linked in as close to real time as possible. With that goal in mind, EV battery analytics specialist Silver Power

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Matrix aimed at seal and EMI issues

The Electrically and Thermally Conductive and Electromagnetic Interference Shielding Materials (ETEMI) project aims to enhance conventional elastomers, liquid silicon rubber and thermoplastics to address sealing and EMI issues at the same time in EVs. This is driving the development of a new class of electrically conductive sealing materials.

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Reducing models of EV behaviour

The development of e-mobility platforms requires a complex interplay between different engineering teams for the mechanical, thermal, electrical, control and software design. ROMs from 3D design tools can be substituted for 1D system simulation models to provide more accurate and detailed results, so teams can make an informed and correct design choice earlier.

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Validating BMS performance

Battery management systems are becoming increasingly safety-critical, as they are responsible for balancing battery cells operating at several hundred volts and maintaining temperatures within narrow working ranges to prevent thermal runaway (writes Peter Donaldson). Gauging the performance of a BMS during r&d, validation, verification and production is therefore of vital and growing importance. Bloomy Controls’ new Flex BMS Validation System is focused on the validation part, particularly in situations where the developer needs to test more than one BMS design.

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StoreDot announces eXtreme approach to charging

StoreDot is developing new a lithium-ion battery technology it calls eXtreme Fast Charging (XFC) that will enable an EV to charge in 5-10 minutes (writes Peter Donaldson). At the heart of it is a silicon-dominated anode that can accept lithium ions much faster than a graphite anode (thanks to silicon’s lower resistance) but controls the tendency of silicon to swell when it accepts those ions that would otherwise generate damaging mechanical forces inside the battery, the company’s CEO Doron Myersdorf says. The Israeli start-up is backed investors Samsung, Daimler, BP and TDK, has raised about $130 million in capital, owns around 100 patents and has 35 PhDs in its team of 120 people, with specialisms in areas including materials science, organic chemistry and electrochemistry. Myersdorf says this number of PhDs provides a level of research power equivalent to two faculties at the Massachusetts Institute of Technology, all focused on the problem of how to charge a battery quickly.

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ABB plans fast-charger network for electric aircraft

As with cars and trucks, electric aircraft need access to an extensive network of reliable fast chargers, and in October it was announced that ABB is to develop a megawatt fast-charging infrastructure for Lilium’s short-haul electric jet

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Nanotech alloy ups HV power

The LISA (Lithium Sulphur for Safe Road Electrification) European project is developing a 20 Ah solid-state lithium-sulphur pouch cell with high gravimetric energy of 450 Wh/kg and volumetric energy density of 700 Wh/litre that will be stable for at least 1000 cycles. The first step is a proof-of-concept 21700 cylindrical cell with a capacity of 3 Ah.

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Multi-kilowatt superconductors

Researchers in Germany have developed a coil with superconducting wires that are capable of transmitting up to 5 kW of power with minimal losses (writes Nick Flaherty). The team, at the Technical University of Munich, worked with Wurth Elektronik eiSos and superconductor coating specialist Theva Dunnschichttechnik on the design of a coil which they believe […]

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Finnish miner to supply Renault with sustainable battery chemicals

In early October, Terrafame announced a deal with Renault in which the Finnish mining company and battery chemicals producer is to supply the car manufacturer with low-carbon and fully traceable nickel sulphate for EV batteries

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Battery vent protects against rapid rises in pressure

As the battery pack is the single heaviest and costliest component of an EV drivetrain, weight reductions in the pack pay dividends in terms of range as well as performance and handling. One of the ways battery manufacturers are looking to reduce weight is to produce packs with thinner walls, which means that they must operate at lower internal pressures and with those pressures carefully controlled.

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AVL and Ford partner to produce fuel cell concept van

AVL and Ford have unveiled the FCVGen 1.0, a concept demonstrator for a fuel cell-electric Ford Transit produced through a project partnership between the two companies and funded under the UK Advanced Propulsion Centre's Advanced Route to Market Demonstrator programme

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Balance Batteries shares details about its range of modules

Balance Batteries, a new Tier 2 supplier of battery modules, recently unveiled its energy storage solutions and spoke with us exclusively to highlight the technologies used in them – some of which are supplied externally, and some developed in-house

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Cell test systems do double duty

EA Elektro-Automatik in Germany has launched a series of bidirectional DC power supplies and regenerative DC loads for testing fuel cell stacks (writes Nick Flaherty). Fuel cells are characterised by determining their electrical resistance, and the performance is usually indicated via polarisation curves by measuring the voltage and current. A durability test after a fuel […]

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Williams Advanced Engineering and Molicell team up for high-power battery applications

In mid-August, Williams Advanced Engineering (WAE) and Molicell announced a strategic collaboration centred on lithium-ion batteries optimised for power density rather than energy density, and with applications in sectors including automotive and mining, as senior commercial manager for battery technology at WAE James Hoxey explains to Peter Donaldson. “Our strategic collaboration enables us to focus […]

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Fast-charging systems boost for UK motorways

In a much-needed push to enable greater uptake of EVs across the UK, charging systems manufacturer Kempower has been selected by UK-based Osprey Charging to supply fast DC charger infrastructure for more than 150 charging hubs due to open nationwide by 2025 (writes Rory Jackson). 1500 units of Kempower’s charging systems will be delivered as […]

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SAF-Holland develops e-axles for refrigerated trucks

Keeping a refrigerated truck powered at all times can be challenging with an all-electric powertrain (writes Rory Jackson). Finding enough battery ‘real estate’ beneath an 18-wheeler’s chassis for long-haul transport of freight is one thing; add a power-hungry refrigeration trailer and drivers could find their battery energy levels running low with irritating frequency. SAF-Holland’s TRAKr […]

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New motor architecture could be a game-changer

At a time when EV manufacturers are eager for efficiency gains of 2-3% in their powertrains, any new technology capable of providing 10% or more would transform the state of competition among vehicle OEMs (writes Rory Jackson). With an eye towards enabling that, US company ePropelled has developed and patented a new type of electric […]

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Eco Charger quad adapted for military use

Electric quadricycle all-terrain vehicle (ATV) developer Eco Charger has teamed up with military vehicle specialist Supacat to adapt the former’s top-of-the-range 4WD model for military use; it displayed an example at the 2021 Defence Systems & Equipment International (DSEI) event in London. Eco Charger COO Jon Hourihan speaks exclusively with Peter Donaldson about the electrification […]

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DSD software optimises e-aircraft powertrain designs

In early August, electrified propulsion engineering consultancy Drive System Design (DSD) revealed that it is working on optimising the propulsion systems for electric aircraft as part of the Driving the Electric Revolution (DER) challenge at UK Research and Innovation. The initial study is intended to evaluate powertrain technology that could be used on a range […]

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Sodium-ion battery development gathers pace

Sodium-ion batteries could displace lead acid in many applications, according to Professor John Irvine, who leads the joint academic/industrial Nexgenna effort under the auspices of the Faraday Institution to develop the next generation of sodium-ion battery technology (writes Peter Donaldson). Speaking exclusively to E-Mobility Engineering, he says they will also be able to compete with […]

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Freedom from rare earth magnets?

A good alternative to magnets made from rare earth elements such as neodymium, dysprosium and samarium – which are expensive, volatile in price and supply and polluting in their extraction – is something of a holy grail for the electrical industry in general and EVs in particular. Enter Niron Magnetics with its Clean Earth iron […]

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Ricardo’s fuel cell bus takes shape

On 17 August, Ricardo announced that it had received UK Government funding to convert a bus to hydrogen fuel cell power as a technology demonstrator. The vehicle, an Alexander Dennis Enviro400, will be operated by Stagecoach as part of the Tees Valley Hydrogen Hub initiative from February next year. Ricardo’s chief engineer for the conversion, […]

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Test system reduces SWaP needs

Dewesoft has developed an new integrated 2000 A and 2000 V sensing system for automotive testing (writes Nick Flaherty). The Sirius XHS-PWR integrates a new current sensor architecture with the DewesoftX software, XCP, or OPC/UA on PoE Gigabit Ethernet with PTPv2 time synchronisation, including high-end data acquisition...

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Inverter enables fast prototyping

Semikron and Silicon Mobility have developed a low-voltage inverter design (writes Nick Flaherty). The 24-96 V inverter platform is aimed at battery-powered and industrial off-road vehicles using a powertrain between 10 and 50 kW. The design combines the SKAI 3LV inverter system from Semikron and the OLEA electric motor...

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New tyre boosts range of solar EV

Bridgestone has designed a tyre specifically for solar-power EVs (writes Nick Flaherty). It has been designed for Netherlands based solar car designer Lightyear and its Lightyear One car to reduce the weight and rolling resistance and so increase its range compared with the regular production tyre. The Lightyear One has a range of 450 miles...

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Nanotech cells process

Nanom in Iceland has developed a nanotechnology process that can turn carbon fibre structures into solid-state batteries (writes Nick Flaherty). The company says this can provide a more than nine-fold increase in performance for lithium-ion batteries, and that it is talking to a wide range of transportation...

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Aluminium batteries advance

Researchers in the US have taken a key step forward towards using aluminium for rechargeable batteries that have far higher capacity than current lithium-ion cells (writes Nick Flaherty). The team, at Cornell University, coated the metal with carbon fibres to improve the performance over more than 10,000 charging cycles and 3600 hours when cycled at a charging rate...

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Super/ultracaps set for new applications in EVs, says UCAP Power CEO

In the wake of Tesla’s sale of supercapacitor/ultracapacitor maker Maxwell Technologies, Gordon Schenk, CEO of UCAP Power, which bought the company, exclusively discussed the future of this high-power, short-duration technology and its EV applications, in which it complements and could replace some batteries (writes Peter Donaldson). Compared with batteries, ultracapacitors have lower specific energy in […]

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Note: electric version now available

Nissan has developed an electrified version of its Note vehicle using a gasoline engine as a generator, as well as its first full EV since the Leaf (writes Nick Flaherty). The Note e-Power uses a three cylinder IC engine to charge a small, 1.5 kWh lithium-ion NMC battery pack that drives dual electric motors in a four wheel-drive hybrid design. This allows the 60 kW/103 Nm engine...

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IGBT-SiC chip cuts inverter costs

Infineon has launched a 650 V hybrid silicon carbide (SiC) and silicon transistor for inverter designs (writes Nick Flaherty). The CoolSiC Hybrid Discrete for Automotive combines a 50 A fast switching IGBT and a CoolSiC Schottky diode to reduce the cost compared to a pure SiC part but provide the high reliability needed...

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OxDrive joint venture unveils self-contained e-hub for farm vehicles

OEMs developing small EVs for agricultural applications, including those intended to have autonomous capabilities, want to focus their efforts on the core agricultural functions and the autonomy (writes Peter Donaldson). Typically, however, they are faced with specifying the driveline, sourcing components and integrating them, says Chris Horton of OxDrive, a joint venture between Performance Projects […]

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High-efficiency inverter

Pre-Switch has developed a 200 kW inverter architecture that achieves more than 99% efficiency with silicon carbide (SiC) transistors (writes Nick Flaherty). The 100 kHz CleanWave200 evaluation inverter uses three discrete, low-cost 35 mΩ SiC MOSFETs from UnitedSiC per switch location...

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Hybrid approach to safe transport

Horizon Aircraft has developed a hybrid electric vertical take-off (eVTOL) aircraft with safety at the heart of its design (writes Nick Flaherty). The Cavorite x5 eVTOL fan-in-wing platform is designed with a redundant gas/electric powertrain to enable safety certification for carrying up to five people. The high-wing canard design has six motors in each wing...

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Virtual AC system controllers

Curtis Instruments has launched a series of programmable AC motor controllers for vehicle traction designs from 24 to 96 V and up to 425 A continuous current (writes Nick Flaherty). The 1238SE series uses the Curtis Vehicle Control Language (VCL), which allows vehicle developers to write powerful logic functions...

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Combined approach to HV tests

Vector and CSM have combined their measurement technologies to validate e-mobility platforms up to 800 V (writes Nick Flaherty). The layouts of the powertrain, the charging components and the HV elements present new requirements for test and validation, which vary from vehicle to vehicle depending on the electrical system topology...

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Quiet word on e-motor

A consortium in the UK is to develop a new quiet motor for urban electric aircraft (writes Nick Flaherty). The two-year InCEPTion – Integrated Flight Control, Energy Storage and Propulsion Technologies for Electric Aviation – project will develop a modular electric propulsion unit for VTOL and conventional take-off and landing aircraft...

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In-vehicle SiC/GaN inverter tester

Yokogawa has developed the fourth generation of its ScopeCorder test system, with a focus on the development of e-mobility systems (writes Nick Flaherty). The DL950 is aimed at applications such as testing EVs with SiC and GaN inverters, as well as ECUs, sensors and in-vehicle comms networks...

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Car data comms chip is a safe bet

Maxim Integrated has launched a 14-channel data management and comms chip for BMSs that can be used in the highest level of safety design, ASIL-D (writes Nick Flaherty). The MAX17852 is aimed at EVs, HEVs and other transportation systems for smart junction box and 48 V automotive...

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Pilot run for solid-oxide fuel cell

Doosan Fuel Cell is to develop a solid oxide fuel cell (SOFC) for ships (writes Nick Flaherty). It will use the cell to drive large marine motors of 9-10 kW, the power depending on the propeller’s design and speed of rotation. Solid-oxide fuel is easier to transport for shipping, and produces...

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Redox flow battery has ships in sight

A European project is using a vanadium flow battery for an electric power system for ships (writes Nick Flaherty). Conoship in The Netherlands and Vega Reederei in Germany are using technology from Vanadium Corp in Canada to develop a next-generation redox fl ow battery stack. It will use a high energy-density...

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Monitor tests insulation remotely

Danisense has launched a residual current monitor (RCM) with a 70 mm primary cable/busbar aperture for testing insulation (writes Nick Flaherty). The aperture allows monitoring of the residual currents in electrical power systems without the need for fast system shutdown. The monitor, called the RCMH070IB+, measures DC and AC...

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Inverter doubles as a charger

Bel has developed a three-phase wide range bidirectional inverter that can be used as an onboard charger as well as a power source for external equipment (writes Nick Flaherty). The key innovation for the BCL25-700-8 is a wide DC output range from 250 to 800 V, with a constant current of 60 A across the voltage range and both single and three-phase...

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Texas unveils ASIL-D wireless BMS

Texas Instruments (TI) has combined its proprietary comms protocol with its sensor chips to create a wireless BMS (writes Nick Flaherty). The use of a wireless BMS is key to the economics of EVs, as it reduces the weight and complexity of wiring and allows the battery packs to have...

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Bring me my charger!

Russian EV charger manufacturer L-Charge announced in June that its first mobile EV charger is in service on the streets of Moscow, where customers can summon it to wherever they are using an app (writes Peter Donaldson). Mounted on a light truck, the charging system can deliver 120-250 kW and can charge an EV as […]

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Bipolar nickel-hydrogen battery for 2021 Toyota Aqua

Toyota’s new Acqua compact HEV comes with a bipolar nickel-hydrogen battery, a world first for a road vehicle according to the Japanese automotive giant (writes Peter Donaldson). Conventional non-bipolar nickel-hydrogen batteries have a much lower energy density than lithium-ion versions but much longer service lives. Compared with the nickel-hydrogen battery in the previous-generation Aqua, says […]

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Solid-state batteries will be big in EVs – eventually

The promise of much safer electrolytes makes solid-state batteries attractive for EVs, particularly passenger cars, and EVs are expected to be their biggest single market (writes Peter Donaldson). However, the technology is far from mature and several challenges remain, according to Dr Xiaoxi He, principal technology analyst at IdTechEx, which has published an in-depth report […]

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Nanotubes boost copper wiring

Researchers at Oak Ridge National Laboratory in the US have created a composite that increases the electrical current capacity of copper wires (writes Nick Flaherty). The research aims to boost the performance and life of components such as electric motors and power electronics. The carbon nanotube (CNT) material can be deployed...

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GaN switch at 650 V ‘sweet spot’

Texas Instruments (TI) has produced a 650 V gallium nitride (GaN) power switch for EV designs (writes Nick Flaherty). It is combined with a silicon gate driver in a single package to simplify the design and management of power systems. The combination has been under test with customers for the past two years, gathering...

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Standard pack for trucks unveiled

Webasto, better known for producing heating and cooling systems, has developed a standardised, modular battery pack for commercial EVs (writes Nick Flaherty). The basic 35 kW, 400 V pack in the CV Standard Battery System has been designed to be used in series or parallel to support 800 V requirements. It uses NMC prismatic lithium-ion cells, and the company has also developed a modular...

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On-site charge packs needs no grid

Jolt Energy has launched a 160 kW high-speed charger for EVs that comes with a replaceable battery pack for when there is no grid connection (writes Nick Flaherty). The MerlinOne measures 230 x 120 x 110 cm and has 200 kWh of internal battery storage. It was developed in cooperation...

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Powertrains project takes off

A project has been announced in the US to develop lightweight and ultra-efficient electric motors, drives and associated thermal management system for large commercial electric aircraft (writes Nick Flaherty). The Aviation-class Synergistically Cooled Electric motors with iNtegrated Drives (ASCEND) project brings together an engineering team at Texas A&M University...

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Switcher steps in with 12 V supply

Power Integrations has unveiled a flyback switcher with an integrated 750 V MOSFET and secondary-side sensing that can be used to provide an alternative 12 V power supply for an EV if its onboard 12 V battery fails (writes Nick Flaherty). The InnoSwitch3-AQ can be used for traction inverters, onboard charger, DCDC bus converters and BMSs. The 12 V battery is used to provide the gate drive...

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Power semiconductors battleground

Even though wide bandgap semiconductors such as silicon carbide (SiC) and to a lesser extent gallium nitride (GaN) are making their presence felt in EV power conversion systems still dominated by silicon (Si), there is more performance to come from Si – and EVs are positioned to take advantage of competition among all three materials […]

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Fast-charge ferries start sea trials

A fleet of fully electric passenger ferries is rolling out in Thailand using motors from Danfoss Editron (writes Nick Flaherty). The first two 24 m-long catamarans are currently being tested in Bangkok. Each one is fitted with two Danfoss EMPMI375-T800 motors. The motors use synchronous reluctance assisted...

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Safe disconnects at up to 1000 V

Staubli has launched a connector for battery packs that supports voltages up to 1000 V for onboard chargers in commercial EVs (writes Nick Flaherty). The PerforMore connector supports 400 A at 1000 V and has a mechanism to allow safe disconnection at that voltage. The goal was to get the most power out...

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Tesla cars to use structural cells

Electric car maker Tesla is to use a new form factor for its battery cells that will form part of the structure of its vehicles (writes Nick Flaherty). The company is also using a new material, silicon powder, and a new roll-to-roll manufacturing process to build the cells. In the current 2170 cell, which is 21 mm in diameter and 70 mm long, the roll of electrodes...

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Open season for EV platforms

The world’s largest contract manufacturer is offering car and truck makers an open platform for EVs (writes Nick Flaherty). Foxconn Technology has developed an electric powertrain, chassis and battery system for a range of EVs that can be made by itself, by OEM partners...

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Parallel processing saves energy

As EVs become more sophisticated to appeal to potential buyers, manufacturers will have to pay close attention to both the power consumption and heat dissipation of sensors and their associated computers if they are to squeeze maximum range from the battery, which will require more parallelisation (writes Peter Donaldson).  Among the most important of these […]

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Double-sided ceramic power module for drive inverters

Engineers in Germany have developed a double-sided ceramic power semiconductor module for more efficient cooling of silicon carbide (SiC) power devices in e-mobility designs (writes Nick Flaherty). The ceramic module developed in the FuCera project dramatically cuts the size of drive inverters by providing more efficient cooling and allows vertical interconnection within the ceramic substrate […]

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Electrolyte detection outs cell leaks

Cell leakage in lithium ion batteries is bad news, so battery makers want to find any that happen during manufacture or assembly so their quality control teams can prevent early failures and minimise warranty costs, while drivers need confidence, safety and low servicing costs. Sandra Seitz from vacuum analysis and test instrument specialists Inficon explained […]

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Dyno development

For ICE powertrain companies looking to transition into e-powertrain engineering, the construction of the new test cells poses on of the biggest cost-barrier to entry, writes Rory Jackson. High-speed dynamometers and test benches capable of measuring the performances of e-motors are inevitably pricey, and many such companies already possess significant testing equipment for cycling combustion […]

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Battery chip boosts EV range

A sensing and balancing chip for battery packs that can extend the range and reliability of EVs has been launched (writes Nick Flaherty). The TLE9012AQU from Infineon Technologies supports up to 12 battery cells with an accuracy of ±5.8 mV over a pack’s temperature and voltage range as well as its life cycle. This accuracy extends an EV’s range...

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ATMP goes electric

Researchers at the University of Exeter, in the UK, have teamed up with Supacat to develop an electric version of the 6 x 6 All-Terrain Mobility Platform, or ATMP (writes Nick Flaherty). The ATMP, first developed in the 1980s, already operates in a range of harsh terrains for military applications using a diesel engine. The conversion to an electric powertrain had to be rugged...

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Relay device retains memory

Researchers at the University of Bristol, in the UK, have developed a new type of electromechanical nanodevice that can be used as a non-volatile memory in high-temperature power systems in EVs and aircraft (writes Nick Flaherty). The leakage current in transistors used as electronic memory devices increases with temperature, so an electromechanical relay built on a micromachined...

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Solar roof sees the light of day

Electric solar car developer Lightyear is working with Dutch multinational Royal DSM on the technology for its solar roof (writes Nick Flaherty). The companies will integrate solar power roofs in various EVs, including cars, vans and buses...

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SiC chips board buses in China

Power modules from StarPower Semiconductor are using the next generation of SiC semiconductors for the first time for electric buses in China (writes Nick Flaherty). Bus maker Zhengzhou Yutong Group is using a 100 A, 1200 V SiC MOSFET transistor from Cree for the StarPower module in an 800 V powertrain design. This will provide the first electric bus design in China to use the SiC widebandgap semiconductor MOSFETs...

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Magnets made using 3D printing

Researchers in Austria have developed a technique to build magnets using additive manufacturing (writes Nick Flaherty). The team, at Friedrich-Alexander- Universitat, worked with researchers at the Graz University of Technology, the University of Vienna and the research institute Joanneum Research to produce the specially...

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Upgrade bring multiple comms

A controller for EV charging systems has been upgraded with a range of comms links (writes Nick Flaherty). The CC613 charge controller from Bender adds connections to Ethernet, Modbus and a powerline communication modem to give developers flexibility in the design of a charging system. This is increasingly important...

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Three-phase SiC module cuts losses

Cissoid in Belgium has launched a three-phase water-cooled SiC MOSFET intelligent power module (IPM) for e-mobility (writes Nick Flaherty). The 1200 V/450 A module has built-in gate drivers, and is designed to optimise the electrical, mechanical and thermal design of the power module and control for electric car OEMs...

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All-in one unit for electric drives

FTCAP in Germany has developed and manufactured a low-inductance capacitor unit that, together with a heat sink and housing, forms an integrated electromechanical device for high-efficiency electric drives (writes Nick Flaherty). The development is part of the H3Top project in collaboration...

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Long trip? Make the car longer

Renault has developed a ‘shapeshifting’ electric car that becomes longer to allow an additional battery pack to be added (writes Nick Flaherty). The 4.4 m-long ‘City’ version of the Morphoz has a 40 kWh battery pack that gives it a range of 400 km. This would be suitable for 90% of local journeys that drivers typically...

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Repurposing Tesla S batteries

EMUS is rolling out a battery management system (BMS) specifically to reuse battery packs from the Tesla Model S (writes Nick Flaherty). The Tesla’s 24 V DC packs have a rated capacity of 5.3 kWh, and consist of six modules. The key is that the cells in each module can end up with different performance characteristics...

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Solar charging’s looking up

Hyundai has developed a roof-mounted solar charging system that connects directly to the powertrain of an electric vehicle (writes Nick Flaherty). Previous roof implementations have used the energy generated to power ancillary equipment such as entertainment systems or...

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Inverter designs gain traction

ON Semiconductor has launched a family of power modules and two reference designs aimed at high-voltage automotive traction inverters (writes Nick Flaherty). The first two VE-Trac modules are intended for main traction inverters of all types of electrically powered vehicles including battery-electric vehicles, plugin hybrids and full hybrids. There are two inverter design platforms for...

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Snow problem for torque software

Porsche Engineering has developed a torque control system for EVs that provides stability in environments such as snow without the need for additional sensors (writes Nick Flaherty). An electric all-wheel-drive vehicle with multiple motors has a key advantage in allowing variable distribution of the drive power every millisecond. This compares to a conventional all-wheel-drive vehicle, where the power is...

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Cutting edge power analysis

Testing and validation of e-drives is a vital element of electric vehicle development, and Japanese manufacturer Yokogawa hopes its latest WT5000 power analyser will be a potent tool for engineers involved in such work. The manufacturer states...

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Gearbox offers e-drive options

Drexler Automotive has developed a modular multi-speed gearbox for EVs (writes Nick Flaherty). Working with German design house Sala Drive, the gearbox has up to 922 Nm input torque, up to 580 kW input power and optional single or dual e-motor drives on the same axle. There is also a move to two-speed transmission powertrains to increase the...

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Combat-ready lithium power

Epsilor has developed a 6T lithium iron phosphate battery for the military that provides an energy density of 2.76 kWh (writes Nick Flaherty). The ELP-24V2740Wh-6T LFP 24 V battery has a lifecycle of more than 3500 charging cycles and improved safety through a high thermal runaway onset temperature and a lower probability of igniting if crushed or...

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‘Full stack’ monitoring system

Fleetonomy has developed an end-to end fleet management system for EVs that includes system data (writes Nick Flaherty). The ‘full stack’ system is based in the cloud and manages the performance and operation of fleets of electric cars. It is currently being used in a project in London called HAVN with a fleet of...

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Interface for standard EV chargers

Delta-Q Technologies has launched a standards-based vehicle charge interface module (VCIM) for AC charging stations (writes Nick Flaherty). The hardware works with Delta-Q’s recently released stackable charging system (SCS) to include compatibility with standard EV supply equipment (EVSE). The module manages the AC current limits in the EVSE and communicates that data to the ‘master’ charger of the...

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E-bike from Nepal uses Ion cloud

Battery management technology developer Ion Energy is working with Yatri Motorcycles in Nepal on an electric motorbike design (writes Nick Flaherty). The bike, called Project Zero, is built from carbon fibre and uses a 30 kW motor running off a 6 kWh lithium-ion battery pack that provides a range of 230 km (150 miles) from...

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Schottky diodes start to motor

Schottky barrier diodes (SBDs) operating at 200 V and with low leakage current are being increasingly used for hybrid and full electric powertrains and inverters (writes Nick Flaherty). There is currently a strong effort towards mechanical integration in 48 V hybrid drive systems, by combining the motor and peripheral circuits...

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Fifth-gen cell voltage monitors

Smart Test Solutions has launched its fifth generation of cell voltage monitoring (CVM) systems for fuel cells, batteries and electrolysis for hydrogen generation (writes Nick Flaherty). This latest version has an extended temperature range of up to 105 C, up from the previous 85 C. The power supply range has also been extended. Instead of using a 5 V supply...

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Gear IC has traction

Allegro Microsystems has launched the industry’s first gear-tooth sensor IC to provide incremental position data for traction motors (writes Nick Flaherty). The ATS17501 provides high-speed switching up to 40 kHz to directly measure rotating ferrous gears up to 30,000 rpm, and provides an incremental encoded output...

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Wheel motor test platform

Nissan has developed a test vehicle to evaluate the use of electric motors on each wheel (writes Nick Flaherty). It is based on the Leaf e+ platform, with front and rear motors and what Nissan calls a new chassis control system. New control technology being developed by the company integrates its electric propulsion and four-wheeldrive control technologies...

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Going everywhere for testing

BorgWarner has converted an Aerial Nomad all-terrain vehicle to all electric operation to test its electric motor technologies and other electric components from suppliers at the system level (writes Nick Flaherty). It is the first high-voltage, all-electric demonstration vehicle to be developed by the company’s Corporate Advanced Engineering group. The new technologies in the test platform include traction inverters...

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Cloud control for e-bus systems

Siemens has launched a cloud-oriented charging system for commercial vehicles that supports power levels from 50 to 600 kW (writes Nick Flaherty). The Sicharge UC family is intended for charging electric buses and utility vehicles at the depot and en route using charging plugs and offboard or onboard pantographs. The 1000 V system works with applications...

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No contact with CAN monitor

Hioki has extended its non-contact voltage test technology to allow developers to monitor CAN bus networks (writes Nick Flaherty). The SP7001/7002 CAN sensors can detect the CAN fl exible data (CAN FD) rate that supports higher rates than the earlier CAN standard, as well as CAN...

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Onboard charger gives it 300%

Finepower has developed an onboard charger based on gallium nitride which, at 3 kW/litre, exceeds the power density of conventional chargers by 300% (writes Nick Flaherty). The water-cooled charger measures 210 x 50 x 60 mm without the housing, and converts input voltages from 85 to 264 V AC, with a maximum power of...

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Electric truck mines own energy

Kuhn Schweiz in Germany has developed an electrified mining truck that does not need external charging; instead it powers its batteries using captured energy (writes Nick Flaherty). The company took a 111 tonne mining truck from Komatsu and replaced the diesel engine with a...

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Scoping out motors/inverters

The accurate analysis of inverter waveforms without interference from switching noise is a key part of evaluating the motor drive circuit, driving the need for a class of test equipment called a ScopeCorder (writes Nick Flaherty). Between 16 and 18% of the total power in an electric car is consumed as losses in the...

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Diversity gives pack balance

Williams Advanced Engineering has developed a battery pack that combines different types of batteries to balance out the needs of peak and sustained power (writes Nick Flaherty). The first version of the Adaptive MultiChem design combines lithium-ion nickel, manganese, cobalt (NMC) pouch cells to provide...

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Bike battery spreads the load

Curtiss Motorcyles in the US has replicated a V8 engine with a distributed battery pack to provide higher efficiency for its latest Zeus model (writes Nick Flaherty). The Zeus has a skeletal space frame anchored to the custom powertrain architecture. “With the battery cells packaged inside eight cylindrical towers configured in a flaring radial vee pattern, we’re able to...

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Battery data gets cloud cover

A battery management start-up has developed a cloud-based battery monitoring service that can handle data from millions of electric bikes and cars on the road (writes Nick Flaherty). The Edison management software from Indian company Ion Energy uses a design called FS-XT, developed by a technology company in France called...

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All-electric ferry set for launch

The world’s first fully electric ferry is undergoing sea trials in Denmark (writes Nick Flaherty). The Ellen electric ferry is powered by a 4 MW battery pack made up of 840 cells that account for 50 tonnes of the ship’s total weight of 747 tonnes. Unlike other electric vessels, the Ellen has no...

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Paradigm shift in gear control

Hyundai has developed an Active Shift Control (ASC) transmission technology for hybrid electric vehicles that it says is the world’s first (writes Nick Flaherty) The system uses software in the Hybrid Control Unit (HCU) to monitor gearshifts 500 times per second, adjusting the...

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CAN-based cooling module

Technotrans has demonstrated a serialised battery cooling module with a CAN interface for standard comms links. It is aimed at electric buses as well as trucks and heavy commercial road vehicles such as those used around mines, harbours and airports (writes Rory Jackson).  “It’s an active cooling solution based on a refrigeration compressor, and we are showcasing a version that runs on...

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E-axle promises lower losses

JLG is developing an electrified aerial lifting platform using electrified axle technology from Dana (writes Nick Flaherty). Dana’s design reduces power losses by up to 20% compared with traditional diesel-powered drivetrains. Dana has developed two approaches to hybridisation and electrification. The first is to use electrified drive systems that fit within current vehicle architectures; the second is...

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BMW/Jaguar e-drive

BMW is to work with Jaguar Land Rover (JLR) to develop next-generation electric drive units that reduce the use of rare earth elements (writes Nick Flaherty). BMW’s fifth-generation powertrain, called eDrive, combines the electric motor, transmission and power electronics in one housing, and the company says it has eliminated the need for rare earth elements for...

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Multi-mount cooling jacket

ETEL in Switzerland has developed a cooling jacket that provides alternative mounting options for its TMB+ torque motors (writes Nick Flaherty). ETEL, part of the Heidenhain group, produces frameless direct drive torque motors with high continuous flux density in the magnetic gap. Effective heat dissipation by liquid cooling increases torque motor performance substantially, and can even...

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Fast, but small and efficient

Researchers at North Carolina State University have built a fast charger for electric vehicles that is at least 10 times smaller than existing systems and consumes 60% less power during the charging process, without sacrificing the charging time (writes Nick Flaherty). Conventional 50 kW fast chargers have to be installed on a concrete slab. With these systems, a transformer takes power from a...

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Volume plan for hydrogen cells

In a key move for hydrogen-powered electric technology, Bosch is starting volume production of fuel cell systems for electric vehicles using technology from Powercell (writes Nick Flaherty). The two companies will jointly develop polymer-electrolyte membrane stacks for fuel cells that convert hydrogen to electricity, and Bosch will make the stacks under licence in 2022. Bosch, a...

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Trash truck to start street tests

Mack Trucks has launched a batteryelectric vehicle (BEV) waste compactor as a demonstrator and will begin real-world testing in 2020 in New York (writes Nick Flaherty). Refuse trucks are a major challenge for electrification, as they have to make multiple stops, often up to 1000 times on a route, and the motors have to provide high torque at...

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Five-seat taxi’s two world firsts

The world’s first five-seat, battery powered electric aircraft has taken its maiden flight (writes Nick Flaherty). A full-scale, full-weight prototype developed by Lilium, in Munich, Germany, has 36 all-electric ducted fan engines that allow it to take off and land vertically, and transition to and from horizontal flight. It has two fixed wings, one main wing at the...

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Bidirectional EV charger

Powertrain manufacturer TM4 has developed a compact bidirectional charger that provides battery charging functionality as well as auxiliary power supply during vehicle operation – using the same power electronic modules to supply a configurable voltage and frequency output to auxiliary devices (writes Lawrence Butcher). In charger mode, the TM4 BCI20 converts AC to DC to charge the electric vehicle’s battery. When a vehicle is in use, the unit becomes a...

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EV ‘fuel economy’ tested

The Automobile Association of America (AAA) has conducted primary research into understanding the effects of ambient temperatures on the range and equivalent fuel economy of five battery electric vehicles (writes Nick Flaherty). Testing was carried out at 20 F (-7 C), 75 F (24 C) and 95 F (35 C). For these temperatures, the effect of various HVAC systems on the battery range and equivalent fuel economy was...

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Top spot for anode material

Paraclete Energy, which makes high capacity, surface-modified silicon nanoparticles for use in battery applications, recently released its SMSilicon/3590, the highest capacity, cycle-stable, validated anode material yet brought to market. It is aimed at anode material companies as a graphite precursor, and lithium-ion battery manufacturers who want to...

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‘Hairpin’ ambition for motors

Researchers in Germany are developing new automated production techniques for electric motors for cars, whether they are powered by batteries or fuel cells (writes Nick Flaherty). The €1.2 million Plant Engineering for the Production of Stators by Hairpin Technology project brings together teams from the Karlsruhe Institute of Technology (KIT) and the Fraunhofer Project Group for...

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Silicon anode breakthrough

Battery manufacturer Amprius claims it has perfected the application of silicon for lithium-ion anodes (writes Lawrence Butcher). Based on its proprietary silicon nanowire technology, it says it has demonstrated breakthrough performance in energy density and cycle life. Silicon anodes have much higher...

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Hybrid drive combo

KEB Automation has launched a modular, scalable combined drive and controller system for hybrid and electric vehicles (writes Lawrence Butcher). The Combivert T6 APD (Auxiliary Power Drives) can interface with any main power source, be that a diesel generator, fuel cells, battery packs or ...

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New-gen composites on show

Lightweight materials are a key element of the integrated engineering approach needed for EV vehicle development, as engineers strive to reduce vehicle weight in order to increase the effectiveness of the battery energy available (writes Lawrence Butcher). A new generation of materials developed by UK-based Alvant provide an interesting option for engineers...

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Bell flags up electric air cab

Bell Helicopter, part of Textron, has unveiled its design for an air taxi using a hybrid electric propulsion unit (writes Nick Flaherty). The Nexus, launched at this year’s Consumer Electronics Show in January, uses six, 8 ft diameter ‘e-propellers’ that can be directed vertically or horizontally. It is based on Bell’s experience with...

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R-R saves battery life at sea

In the course of developing electric propulsion systems for a range of marine vehicles, Rolls-Royce has produced a new lithium-ion energy storage system called SAVe Energy (writes Rory Jackson). It was in development for 18 months before commencing certification by...

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Bus is on route to the future

Daimler has developed an electric bus platform that will accommodate the next generation of batteries and fuel cells (writes Nick Flaherty). The powertrain of the eCitaro bus is based on the proven ZF AVE 130 electric axle, with 125 kW electric motors at the wheel hubs providing...

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Testing facility for e-motors

New testing laboratory for E-mobility drives The Von Roll institute in Breitenbach, Switzerland, recently expanded the capabilities of its already comprehensive test facilities with the addition of a new lab, dedicated to the testing of e-motors specifically for...

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Diesel digger goes electric

US motor maker Dana has developed a custom electric drivetrain for compact excavators (writes Nick Flaherty). The drive for Mecalac’s e12 electric compact wheeled excavator uses Dana’s Spicer 112 axles and a Spicer 367 shift-on-fly transmission. The 146 kWh LiFePO4 batteries in the area previously occupied by...

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eVTOLs distribution deal

VerdeGo Aero, a US company with the goal of producing an eight-rotor eVTOL air taxi – and headed up by Erik Lindbergh, great-grandson of aviation pioneer Charles Lindbergh – is developing a distributed power system that could be marketed to other eVTOL aircraft developers (writes Lawrence Butcher). The company’s design, referred to as...

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Smoothing road to electric

In recent months, efforts by Tesla and Toyota to bring electrification to semitrailers for road freight have made the headlines (writes Lawrence Butcher). The goal of full electrification, as sought by these companies, is an admirable one, but in the near term, there is much that can be achieved through...
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