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ECUs

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

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Measuring methods and equipment

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

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Fuel cells

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

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Connectors

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

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eAxles

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

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Magnetics

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

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Lightweight materials

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

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Onboard Chargers

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

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Radial flux motors

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

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Inverters

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