Deep Insight

E-motor production technology

Manufacturing an EV powertrain with a permanent magnet synchronous motor or an induction motor requires fusion of precise metallurgy, high-speed automation and stringent thermal-electrical isolation. Optimising this process...

Deep Insight

Fast-charger manufacturing

EV charging has reached an inflection point as an industry. The fundamental power electronics of fast charging are largely mature. At the time of writing, the bottleneck is no longer topology or semiconductor physics, it is around...

Deep Insight

Lightweight chassis joining

A lighter touch Nick Flaherty gets stuck in to the range of new production techniques, fasteners and adhesives needed for lightweighting EVs Lightweighting is an important strategy that is helping the auto industry address environmental regulations around range and emissions, while continuing to enhance comfort and safety for the driver. As manufacturers ramp up EV […]

Deep Insight

Drivetrain data acquisition

Testing times Nick Flaherty delves into the science and practicalities of data acquisition in the world of automotive manufacturing Automotive manufacturing requires a set of complex project phases during its development process covering the requirement specification, system design and simulation, component design, evaluation, vehicle integration and validation. These can have high costs, which can limit […]

Deep Insight

Fuel cell adhesives

Developing adhesives and sealing materials appropriate for hydrogen-based fuel cells and electrolysers is a sticky challenge. Nick Flaherty investigates. Hydrogen is the smallest of all molecules, meaning that the adhesives and sealants used for fuel cells must ensure a very tight seal to prevent diffusion.

Deep Insight

Fast charging

Nick Flaherty looks at the development of ultrafast-charging stations around the world. Drivers of EVs are often frustrated by the speed of charging. While home chargers use AC at power rates to 22 kW, fast charging covers direct current (DC) charging at a power of 30 kW.

Deep Insight

Magnetic materials

Global politics is driving design decisions for magnets in motors, as Nick Flaherty explains. Rare earth materials, also known as rare earth elements (REEs), have become much more well known in recent months because their critical role in the e-mobility industry has become high-profile.

Deep Insight

Megawatt Charging

In 2018, the Charging Interface Initiative (CharIN) formed the Megawatt Charging System (MCS) Task Force to develop a robust, scalable and interoperable system for fast charging of electric heavy-duty vehicles. The goal was to meet the growing demand for fast, efficient charging of high-capacity batteries in commercial heavy-duty vehicles.

Deep Insight

Motor cooling

E-motor cooling technology is evolving rapidly, as Peter Donaldson finds out Discussions on thermal management in electric vehicles (EVs) usually focus on the battery because of the risk and potential consequences of thermal runaway. However, keeping motors comfortable in terms of temperature is also

Deep Insight

HIL Testing

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