Friday, September 29, 2023

Two days left to join the Charged Virtual Conference on EV Engineering


Next week, Charged is hosting a virtual conference on EV engineering that’s free to attend. The conference includes live webinar sessions with interactive Q&As and on-demand webinars. View the daily session schedule online here.

All live sessions will be recorded and available to view after the broadcasts. You can access the recorded videos on each session’s registration page.

Just like the content Charged brings you every day, conference topics will span the entire EV engineering supply chain and ecosystem, including motor and power electronics design and manufacturing, cell development, battery systems, testing, powertrains, thermal management, circuit protection, wire and cable, EMI/EMC and more.



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The EV Network and bp pulse open public EV charging hub with 180 charging points in the UK


UK charging infrastructure supplier bp pulse, along with The EV Network and events management company NEC Group, have partnered to open a bp pulse Gigahub on the NEC campus at the heart of the UK’s national motorway network.

“The strategic placement and impressive scale of this charging hub within the UK’s transport infrastructure offers reassuring support to drivers journeying between cities,” said Reza Shaybani, CEO and co-founder of EVN.

The Gigahub can accommodate 180 EVs. It is equipped with sixteen 300 kW DC chargers capable of charging 30 EVs simultaneously and an additional 150 points for 7 kW charging.

The EV Network worked with bp pulse on several projects in 2023. EVN designed, developed and constructed the facility after signing a long-term contract with the NEC Group to bring charging infrastructure to its campus. bp pulse will operate the hub.

Source: bp



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American Battery Factory and First Phosphate to produce LFP cathode active material in North America


American Battery Factory (ABF) has partnered with Canadian mineral development company First Phosphate to produce more than 40,000 tons of lithium iron phosphate (LFP) cathode active material (CAM) annually for the battery storage sector in North America.

The agreement envisions LFP CAM manufacturing of $500 million to $1 billion annually at future raw material costs. First Phosphate will source and supply local raw materials and manage logistics for ABF’s LFP CAM production process and will work on close integration into ABF workflows. 

ABF and First Phosphate will begin a homologation process whereby First Phosphate raw materials will be used to produce LFP CAM for ABF’s battery cells and energy storage products. First Phosphate has access to clean igneous anorthosite phosphate-bearing rock in Quebec, Canada, which it intends to purify into a large quantity of battery-grade purified phosphoric acid. The companies will consider the possibility of locating certain facilities at the Port of Saguenay, Quebec.

ABF projects sustained annual demand for LFP CAM starting in 2026 and expects to reach full production by 2028 at its first planned LFP battery manufacturing facility in Tucson, Arizona.

“Stationary energy storage and telecom applications are already an established market application for LFP batteries in North America alongside the rapidly expanding EV sector,” said John Passalacqua, CEO of First Phosphate.

Source: American Battery Factory



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2,100-passenger electric Ro-Pax ferry ship features powertrain from Wärtsilä and batteries from Corvus


Australian shipbuilder Incat Tasmania is building a gigantic new battery-electric ferry.

The lightweight catamaran has an overall length of 130 meters and a capacity of 2,100 passengers and 225 vehicles. It is being built for Uruguayan ferry operator Buquebús, which plans to operate the vessel between Argentina and Uruguay.

Finnish technology group Wärtsilä will supply the energy management, power conversion and DC shore charging systems, as well as the 40 MWh battery modules, the DC hub, the eight electric motors, eight Wärtsilä axial-flow WXJ1100 waterjets and the propulsion-control system. 

“The eight e-motor waterjet propulsion configuration is the most efficient available on today’s market for this speed range and type application,” said Roger Holm, President of Wärtsilä’s Marine Power business.

Norwegian maritime industry battery provider Corvus Energy will supply the battery systems to Wärtsilä.

The design of the vessel’s lightweight Dolphin NextGen battery is based on the architecture of the Corvus Blue Whale ESS. The four-year development program of the Blue Whale included improvements in battery chemistry, mechanical and electrical design, and software building blocks.

Delivery of the powertrain and battery systems is scheduled for the end of 2024, and delivery of the vessel is expected in 2025.

Source: Wärtsilä



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Sion Power partners with Citrine Informatics to accelerate lithium metal EV battery development


Sion Power, a US-based battery developer, has entered into a multi-year agreement with Citrine Informatics to use the Citrine platform for artificial intelligence (AI)-guided product development.

The partnership will focus on the digitalization of R&D and product development workflows for next-generation battery products.

“The Citrine Platform allows us to accelerate our development of the next-generation lithium metal battery with twice the energy density of a conventional lithium-ion battery,” said Tracy Kelley, Sion Power’s CEO.

Source: Sion Power



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Thursday, September 28, 2023

Revolutionize your retail business with innovative EV chargers


The electric vehicle revolution is transforming the way we think about transportation, and as a retailer, you have a unique opportunity to be at the forefront of this transformative movement. EV chargers are not just the future – they are the present. Embracing the innovation and adoption of EV chargers can set your business on a path towards sustainable success. 

Consider that installing EV chargers isn’t just about being environmentally friendly – it’s about driving your retail business forward. Offering EV charging facilities attracts more foot traffic, extends customer dwell time, and creates brand loyalty among EV owners. Be a part of the green movement and watch your sales soar!

Download the eBook to gain a deeper understanding of:

  • The accelerated EV adoption projection
  • Choosing the right location
  • The importance of convenience for customers
  • City reconfigurations
  • How geospatial data can help you craft the right solution 

Build your strategy to implement tomorrow’s vehicles with geospatial!



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SAKOR launches new series of dynamometers for testing electric motor efficiency


SAKOR Technologies, a manufacturer of dynamometer systems, has developed a series of dynamometers to assess the efficiency of electric motors.

The SAKOR dynamometers can test two- to eight-pole motors from 10 watts to 3 MW according to standards including IEC 60034-2-1, IEEE 112B and Canadian standard C390-93. These testing dynamometers have been optimized so that individual machines can test different motor sizes while maintaining accuracy tolerances. SAKOR systems meet the standards’ tight tolerances and exacting requirements regarding data precision and accuracy.

“We have defined this line of systems to give the maximum utility per machine and make it most cost-effective for the customer. By optimizing equipment to test the widest range of motor sizes with one system while staying within required accuracy levels, customers will need to buy the fewest number of machines at the lowest total cost,” said Randal Beattie, President of SAKOR. 

Source: SAKOR



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Wednesday, September 27, 2023

A cutting-edge system-on-chip designed to replace traditional EV microcontrollers (Webinar)


Silicon Mobility invented the Field Programmable Control Unit (FPCU), a cutting-edge system-on-chip designed to replace traditional microcontrollers in the automotive sector. Over the past few years, Silicon Mobility has been diligently developing the 2nd generation of FPCUs, known as the OLEA® U FPCU series, now opening access to lead customers.

The OLEA U FPCU series has been built to address current and future needs in the automotive industry for real-time, safe and secure multi-control applications and functions grouping, including advanced control algorithms based on edge AI armed with protection against post-quantic cybersecurity threats.

During this webinar at the Fall Virtual Conference on EV Engineering we will go over the FPCU architecture and unveil the key new features of the OLEA U FPCU series:

  • Advanced eXecution and Events Control (AxEC 2.0), a data processing and real-time control unit based on programmable hardware and configurable peripherals with multi-FLU clusters.
  • Safety Integrity Level agent (SILant 2.0), dedicated to the FPCU and the system functional safety.
  • Flexible Hardware Security Module (FHSM), a sub-system dedicated to cybersecurity combined with a hardware programmable cluster supporting yet unidentified threats.
  • Multi-core CPU and virtualization, based on ARM Cortex-R52 clusters for multiple applications/functions executions into a single controller.

OLEA U is a scalable series of FPCUs that share a common software architecture which can be reused across different applications, saving time and money.

Reserve your spot—it’s free!


Other sessions at our Fall Virtual Conference include:

Challenges in EV testing: data acquisition for battery testing, vehicle dynamics and acoustics (Webinar)

This webinar, presented by imc Test & Measurement, is divided into three different topics for EV testing tasks. First, we speak about challenges in HV component and battery testing and present solutions including electrical, mechanical and thermal tests.

Then we look at challenges and higher demands on measurement technology to record vehicle dynamics parameters and present sensor solutions.

Last, we discuss acoustic challenges including pass-by noise, interior noise and how the sound power of individual vehicle components and assemblies can be determined.

Reserve your spot—it’s free!


See the full session list for the Fall Virtual Conference on EV Engineering here.

Broadcast live on October 2-5, 2023, the conference content will span the EV engineering supply chain and ecosystem, including motor and power electronics design and manufacturing, cell development, battery systems, testing, powertrains, thermal management, circuit protection, wire and cable, EMI/EMC and more.



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GreenFlux and Hubject partner to enable Plug & Charge


Dutch EV charging software provider GreenFlux has announced its implementation of the Plug & Charge technology of Berlin-based charging network Hubject

“The addition of Hubject’s Plug & Charge technology further allows GreenFlux to promote renewable transportation at scale,” said Suthalan Gnanes, GreenFlux Managing Director and Chief Commercial Officer.

According to GreenFlux, its services allow charge point operators (CPOs) and eMobility service providers to scale their operations with cloud-based, hardware-agnostic EV charging solutions. With the new partnership, GreenFlux’s CPO customers will be able to offer the Plug & Charge feature, based on the ISO 15118 protocol, to their clients once charge station firmware has been updated and required certificates are in place. 

EV drivers using Plug & Charge will be able to directly pay for charging sessions. Authentication begins as soon as the vehicle is connected.

Source: GreenFlux



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ICL inaugurates $400-million US battery materials manufacturing plant


Minerals specialist company ICL has inaugurated a large-scale battery materials manufacturing plant in St. Louis, Missouri.

The $400-million plant will manufacture materials for lithium iron phosphate (LFP) batteries and will be operational by 2025 to meet growing demand from the energy storage, EV and clean energy industries for battery materials produced and sourced in the US. ICL’s investment was supplemented by a $197-million grant from the US Department of Energy.

The 140,000-square-foot facility will produce 30,000 metric tons of LFP annually.  ICL has engaged St. Louis-based McCarthy Building Companies as general contractor for the project, and has also partnered with Taiwan-based LFP battery material manufacturer and global IP licensor Aleees.

“ICL is building the first North American, commercial-scale plant for this critical component required by the energy storage, mobility and infrastructure end markets, and this investment in St. Louis will create more than 150 high-paying union and professional positions in our hometown,” said Phil Brown, President of ICL’s Phosphate Division and its MD for North America.

Source: ICL



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Paired Power and Monarch Tractor bring off-grid solar charging to California vineyard


Carr Winery sources hand-harvested organic grapes from Santa Barbara County vineyards. Since July, the company’s Kaerskov Vineyard has been using an electric “driver-optional” tractor that’s driven by 100 percent off-grid solar energy.

At the vineyard, Monarch Tractor’s MK-V electric tractor is charged by Paired Power solar chargers, enabling the vineyard to significantly reduce its utility cost and its reliance on fossil fuels.

In addition to charging the tractor directly, Paired Power’s solar-powered DC fast charging stations also charge a swappable battery cart during the day, providing the tractor with a full recharge for night-time operation.

According to Monarch, the MK-V tractor offers farmers the benefits of advanced collision prevention, human detection and power take-off protection, along with savings of over 60 percent on fuel and service.

The agricultural industry is a major contributor to greenhouse gas emissions. One challenge to electrifying agricultural equipment is the fact that many agricultural sites are located at the end of grid distribution lines, which means that the supply of electricity may be unstable. Upgrading power lines to stabilize the supply coming from the grid can be costly and result in years of delays.

The installation of Paired Power’s chargers at Kaerskov Vineyard was made possible by a grant from Santa Barbara County’s Air Pollution Control District’s Clean Air Grant, along with support from CalCom Energy.

“Our mission at Monarch is to elevate overall operations, improve farmer profitability, and pave the way for sustainable farming,” said Praveen Penmetsa, co-founder and CEO of Monarch Tractor. “Pairing the electric MK-V with renewable charging infrastructure like Paired Power’s solar solutions brings us closer to a farming future that is powered by clean energy solutions.”

“Our high-powered solar charger was designed with fleet applications in mind, as we know that providing a convenient means to charge electric tractors will be essential in the adoption of electrified farming,” said Tom McCalmont, co-founder and CEO of Paired Power. “Our charging solutions are scalable to ensure that we can continue to provide easy renewable charging as electric fleets expand.”

Sources: Paired Power, Monarch Tractor



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Data indicates EVs bring significant health benefits for truck drivers


Charged regularly speaks with execs at companies involved in pilots of electric trucks. These folks invariably tell us about the (sometimes unexpected) rave reviews that EVs get from drivers, who love the quiet and the lack of vibration. Of course, they also love not having to breathe diesel exhaust.

A new article from the Natural Resources Defense Council adds some data to the anecdotes, quantifying the serious health risks truckers face, and explaining how electrification could help improve the health of the 3.5 million truck drivers in the US.

Among the harmful pollutants found in diesel exhaust are nitrogen oxide (NOx) and particulate matter. PM2.5, commonly known as soot, forms a complex aerosol system, and its ultrafine size allows it to easily enter the lungs. Regular exposure to PM2.5 has been linked to various respiratory diseases and cardiovascular illness, making it a significant concern for truck drivers.

Heavy-duty trucks represent only six percent of vehicles on US roads, but in 2020 they generated 59 percent of NOx emissions, 55 percent of particle pollution, and 26 percent of transportation-based greenhouse gas emissions, according to research by the American Lung Association.

In-cabin pollution causes daily exposure to air pollutants for drivers. Truck cabins can accumulate unhealthy levels of PM2.5 and NOx, and drivers who spend long hours in their trucks can develop respiratory and cardiovascular problems. According to the American Cancer Society, workers with prolonged exposures to diesel emissions have been found to have higher lung cancer death rates than unexposed workers.

Medical research indicates that truck drivers regularly exposed to diesel exhaust face an elevated risk of lung cancer. The International Agency for Research on Cancer classifies diesel exhaust as a Group 1 human carcinogen.

A 2018 study on occupational health disparities among long-haul truck drivers in the US revealed significant differences in health risks compared to other sample groups. The long-haul truck driver group had higher mean scores for both cardiovascular disease and metabolic disease risk.

Furthermore, truck drivers are less likely to have health insurance coverage compared to other workers (15 percent are uninsured, versus 10 percent of all US workers).

Of course, it isn’t just truck drivers who are at risk. Studies have shown that communities with high exposure to diesel particulate matter have higher rates of asthma.

Along with the smoke comes noise, which can cause drivers to suffer from hearing loss, dizziness, headaches, high blood pressure and anxiety. A study conducted in 2015 found that traffic noise was associated with cardiovascular problems.

The American Lung Association predicts that the transition to zero-emission trucks could prevent 66,800 premature deaths, 8.5 million lost workdays, and 1.75 million asthma attacks over the next 30 years.

The NRDC concludes that “zero-emission trucks hold immense potential for reducing harmful emissions and improving the health and well-being of millions of people.”

What are we waiting for, folks?

Source: Natural Resources Defense Council



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Inventec and Renesas jointly develop proof of concept for EV-connected gateways


Taiwanese computer server manufacturer Inventec and Japanese semiconductor supplier Renesas Electronics have established a partnership to build automotive-grade gateway solutions for EVs.

The companies will develop a proof of concept for connected gateways based on the R-Car system-on-chip (SoC) from Renesas. Under the deal, Renesas will supply Inventec with R-Car SoCs, analog and power products, as well as engineering support, to create a proof of concept for next-generation in-vehicle connected gateway systems. 

The first proof of concept will provide cybersecurity and OTA for connected gateway apps and is expected to be available through Inventec from the second quarter of 2024.

“The integration of our technology with Renesas’s field-proven R-Car SoC platform will enable us to reach a new base of EV customers in search of advanced intelligent automotive solutions around the world,” said Sam Yeh, Chairman of Inventec.

Source: Renesas



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Tuesday, September 26, 2023

Learn more about testing EV charging hardware with Hardware-in-the-Loop simulators (Webinar)


Testing charging stations is a critical component of ensuring their reliability and functionality in the rapidly evolving EV ecosystem. Using HIL simulators for these tests provides a controlled and efficient environment for assessing various aspects of the charging station performance. These simulations can replicate real-world scenarios such as various EV models, the evaluation of charging speed, various power levels, compatibility with different charging standards, and other charging parameters.

Also, simulators enable thorough testing of software components, such as user interfaces and communication protocols.

Join this webinar at the Fall Virtual Conference on EV Engineering to learn about the dSPACE Smart Charging solution that allows the simulation of the electric vehicle as well as the charging equipment on signal level and power level, offering a powerful workflow to bring electric vehicle behavior on power level to the lab.

Reserve your spot—it’s free!


Other sessions at our Fall Virtual Conference include:

Optimizing Power and Information Flow in EV Systems: Strategies for Harness Protection and Routing

Session Banner

As the automotive industry shifts focus toward EVs, the need for harness protection remains high.

In this webinar, presented by tesa tape, we will outline the problems currently faced, application areas and testing, and design solutions. We will look to the future and discuss innovations in the field as well as outline how tesa partners with our customers to find tomorrow’s solutions, today.

Reserve your spot—it’s free!


See the full session list for the Fall Virtual Conference on EV Engineering here.

Broadcast live on October 2-5, 2023, the conference content will span the EV engineering supply chain and ecosystem, including motor and power electronics design and manufacturing, cell development, battery systems, testing, powertrains, thermal management, circuit protection, wire and cable, EMI/EMC and more.



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Vitesco Technologies develops new power module for EV inverters


Vitesco Technologies, a drive and electrification solutions provider, is developing a transfer-molded power module for EV inverters.

During the transfer molding process, the power electronics are sealed under a dielectric material that protects the components, making them robust, cost-effective and reliable, the company said. The power module consists of three over-molded half-bridges, and forms the core of an inverter system, which controls the drive energy and the energy recovery (recuperation) in high-voltage EVs. 

Vitesco will manufacture the power modules at its Nuremberg electronics plants and supply them to a major automaker starting in mid-2025. The overmold power modules combine silicon carbide (SiC) chip technology with overmolding for higher power density, lower cost and reduced weight.

“A very deep system competence is necessary to ensure that a sub-module of this kind, which forms the core of the inverter, can be successfully integrated into the full system,” said Michael Horbel, Head of Product and Platform Management for High-voltage Inverters at Vitesco Technologies. “Our degree of electronics modularity and scalability enables us to offer more flexibility in terms of customer-specific interfaces.”

Source: Vitesco Technologies



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NOVONIX doubles capacity target for US anode material production


NOVONIX, a battery materials and technology company, has provided an update on production from its proprietary continuous-induction furnaces at its Riverside, Tennessee facility.

In a recent production campaign, the site’s Generation 3 furnaces produced material met all specifications while also reaching the equipment design throughput targets. Analysis showed that the company’s GX-23 grade synthetic graphite satisfied all physical and electrochemical requirements. The continuous output from a single Generation 3 Furnace, producing multiple tonnes of material, met the product graphitization target. 

The company is updating the facility’s production target to up to 20,000 tons per annum (tpa), from 10,000 tpa. KORE Power and other prospective customers will benefit from this updated throughput and the company expects engineering work to validate the redesign in the first quarter of 2024. NOVONIX aims to deploy additional mass production equipment for the start of commercial production for KORE Power in late 2024.

NOVONIX is working with the US Department of Energy and government initiatives like the 45X Advanced Manufacturing Production Credit to enhance its cost structure.

“The results of our ongoing production campaigns clearly demonstrate NOVONIX’s path to profitable production through graphitization furnace technology,” said Dr. Chris Burns, CEO of NOVONIX. “Over several production campaigns, the furnaces delivered in-spec product at a mass scale, reaching our target design throughputs.”

Source: NOVONIX



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ShockFlo’s new S1 home EV charger


Charging station manufacturer ShockFlo has released a new Level 2 residential EV charger. The S1 EV Home Charger comes in 40-amp and 48-amp versions. It includes an RFID card reader, an IP65 waterproof rating, a dedicated app and multiple installation options.

Drivers can use the ShockFlo app to schedule charging times during non-peak hours, monitor and adjust the charging current, and remotely control charging.

The S1 can be installed hard-wired or with a NEMA 14-50 plug for portable charging.

Safety features protect against lightning, current leakage, ground faults, low or over-voltage, over-charge, over-heating and over-current.

“Melding unprecedented speed with utmost safety, we’ve bridged the gap between today’s needs and tomorrow’s possibilities,” said Jack Lee, founder of ShockFlo. “Whether you prioritize swiftness, security, or the sheer joy of intelligent technology, the S1 promises to supercharge your EV experience.”

Source: ShockFlo



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Precision micro-components for IGBTs and MOSFETs in EV applications (Whitepaper)

Metal-oxide semiconductor field-effect transistors (MOSFETs) are electronic devices used to switch or amplify voltages in circuits. Insulated gate bipolar transistors (IGBTs) are suitable for high-voltage, high-current applications and are designed to drive high-power applications with a low-power input.

In the journey to enhance EV reliability through thermal management, and increase efficiency in converters and inverters, it is crucial to utilize high-performance components. COINING’s range of solder preforms, bond pads, copper clips, bonding wire and ribbon play a vital role in the electric vehicle’s entire system. These solutions offer cost-reduction benefits and minimize process variability, contributing to overall system optimization and enhanced reliability.

COINING’s high-performance engineered materials are optimized for the challenges of EVs applications. Our elaborate selection of engineered alloys will enhance the overall performance of the assembly process by increasing the production yield and lowering the defect rate. EV designs will benefit from the superior heat dissipation characteristics of optimized alloys. COINING offers hundreds of alloys and is flexible with customization utilizing our integrated manufacturing from melting to final packaging of stamped components. The Coining alloy selection chart can help narrow the search to specific alloys or identify needs for customized products.

This whitepaper provides an overview of the significance of high-power electronic components in battery systems, focusing on charge ports: power supply AC/DC DC/AC, MOSFET and IGBT. The whitepaper showcases COINING’s EV components and how they impact reliability, thermal management, and overall enhanced performance.



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Monday, September 25, 2023

Avery Dennison launches new Volt Tough electrical insulation tapes for EV batteries


US adhesive manufacturing company Avery Dennison has launched a newly developed portfolio of electrically insulative, single-sided filmic tapes for EV battery packs.

The Volt Tough portfolio includes tapes that incorporate features for OEMs and converters, including options for curved geometries, high abrasion-resistant options, color options for vision inspection systems, flame-retardant options for UL-94 and other flammability standards, high dielectric strength with thin, consistent profiles enabling higher energy density and instant bonding to enable efficient production. 

In comparison to EV battery spray coatings, Volt Tough comes at lower cost, eliminates curing time, has thinner profiles for better heat flow and offers extended shelf life, the company said. Avery Dennison also offers customized options like quick-stick and high-tack adhesive formulations, in addition to single-coated foam tapes that improve insulation.

“With every major OEM currently electrifying their fleets, engineers are facing new challenges in dealing with high voltages in their battery packs,” said Scott Krusinski, Market Manager, Energy Storage at Avery Dennison. “The Volt Tough portfolio is specifically engineered to enhance electrical insulation in EV battery packs. Proper insulation is critical to protecting cells and other sensitive components to prevent electrical arcing that can lead to shorting and fires.”

Source: Avery Dennison



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UK auto industry execs slam Sunak’s abandonment of net zero pledges


In UK politics, climate change policies cut across party lines. Boris Johnson’s Tory government set an official goal of reaching “net zero” emissions by 2030. This translated to a wide range of pro-EV policies, and the results can be plainly seen in London, which has become one of the world’s most charged cities.

Now Rishi Sunak’s Tory government is steadily reversing or watering down many of his party’s key net zero pledges. Among other measures, the country will push back the previously-announced 2030 phase-out of new petrol and diesel car sales.

Several Tory MPs immediately criticized the reversal. Boris reminded Rishi that businesses need to be assured that the government is committed to the green transition. Dr. Anna Valero, a member of Chancellor Jeremy Hunt’s economic advisory council, called the reversal “yet another example of policy volatility that prevents businesses taking the long-term investment decisions needed for a stronger, more resilient and sustainable economy.”

Meanwhile, across the aisle, support for e-mobility seems lukewarm at best. A spokesperson for the Labour Party described Sunak’s plans as “a total farce,” but refused to say if the party would consider reinstating the 2030 ban if and when it returns to power. In July, Labour Party leader Keir Starmer expressed opposition to London’s plan to extend its low-emission zone, which has been a major impetus to the electrification of taxis and ride-share vehicles in the capital.

Meanwhile, what’s left of the UK’s auto industry is ever so cross about the flip-flop. Ford’s UK Chair Lisa Brankin said the auto industry is investing to meet the challenge of electrification, pointing out that Ford has committed £40 billion to electrifying its cars, and has announced some £430 million of investment in the company’s UK facilities. Ford is (or was) planning even more investment, based on the 2030 target, which Brankin called “a vital catalyst to accelerate Ford into a cleaner future.” She added that business “needs three things from the UK government: ambition, commitment and consistency. A relaxation of 2030 would undermine all three.”

Dr. Andy Palmer, who has been the CEO of Aston Martin and the COO of Nissan, told The Independent that abandoning the 2030 ban would be a “significant step back for the UK’s global leadership in fighting climate change.” Dr. Palmer, who now runs EV charging firm Pod Point, said companies have invested heavily in Britain “specifically because of the 2030 deadline,” and that they will “understandably feel cheated by this sudden change in direction.”

“Take it from me, automakers will base themselves where the batteries are made,” said Palmer. “We have a very short window to act to get our industry in shape for tomorrow. China is leap years ahead of us, so is America, so is the EU.”

The Society of Motor Manufacturers and Traders is also “concerned” about Sunak’s plans. Chief Executive Mike Hawes pointed out that the industry has invested billions of pounds in EVs, batteries and related technologies, largely thanks to government support. “So we are questioning…what is the strategy here? We do not know quite what is going to happen now,” he told the BBC.

The Institute for Public Policy Research pointed out that the UK government recently agreed to hand Jaguar Land Rover up to £500 million in subsidies for a new battery gigafactory. “What is the point of investing half a billion pounds of public money in an electric battery factory only to abandon the petrol and diesel phase-out?” asked Associate Director Luke Murphy. “Investors need stability and certainty. While other countries race ahead, the UK is going into reverse gear.”

Source: The Independent, The Week



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Marelli releases new range of multipurpose smart actuators for hybrids and EVs


Marelli has launched a new range of multipurpose smart actuators for simplifying actuation and thermal management in hybrids and EVs.

Marelli’s new smart actuators have an electronic module that autonomously controls and links the actuator to the EV’s electronic network. The device has a flexible, modular and scalable mechanical design, to fit complex vehicle electronics and transmission configurations, and a software management system designed for simple integration. The overall solution allows customization and installation within the vehicle, is compact and lightweight, features onboard diagnostics, and is cyber-security-ready. 

Marelli has also developed an integrated Thermal Management Module (iTMM) for EVs, which combines the cabin, battery and e-powertrain thermal systems into one single component.

“As future cars are expected to include more than 100 actuators with different missions and purposes, this solution will help carmakers to reduce complexity and ease the integration in vehicles’ mechanical and electronic environments,” the company said.

Source: Marelli



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Friday, September 22, 2023

Autel Energy launches MaxiCharger AC Ultra EV charger for European markets


Charging hardware manufacturer has added a new Level 2 EV charger to its product range. The MaxiCharger AC Ultra is an IEC-certified, dual-socket commercial AC charger, and is now available worldwide as a European-standard 22 kW charger.

“MaxiCharger AC Ultra can output 22 kilowatts of power simultaneously, meaning two vehicles can charge at the same time, each receiving 22 kW,” says Kelvin Cao, Autel’s VP of Global Marketing. “It’s great for businesses that need a sleek EV charging option for employees, customers and guests.”

The OCPP-compliant MaxiCharger AC Ultra features an eight-inch LCD touchscreen, an IP54-rated enclosure, an RFID card reader, and multiple customization options such as a credit card reader, a pedestal, energy meters and customizable logo opportunities.

Revenue-generating opportunities include the ability to provide charging rate discounts based on customer profiles (first-time or loyal users) and driver groups (taxi or ride-hailing service drivers), and the ability to monetize advertising. The touchscreen allows businesses to engage with customers with branded videos or slideshows, or earn added revenue from third-party video content.

“Our cloud platform is the brain behind a full-scale charging station,” continues Cao. “Everything is designed to enhance the operator’s experience. Whether you have one MaxiCharger or 100, the cloud can handle it all with ease, putting operators in full control of their business.”

Source: Autel Energy



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Thursday, September 21, 2023

Vanner begins serial production of liquid-cooled converter for EVs with SiC solid-state switching


Power conversion specialist Vanner has started serial production of a liquid-cooled converter with silicon carbide (SiC) solid-state switching for hybrid, battery-electric and fuel cell vehicles.

Vanner has designed a 17.1 kW, 600 A converter using its Hybrid Beltless Alternator (HBA), which is a 17.1 kW, 300 A, 600 VDC to 24 VDC air-cooled converter. It is liquid-cooled to minimize the footprint, and is IP67-rated. It is available in two models: liquid-cooled HBA for hybrid vehicles and liquid-cooled Electric BA for battery and fuel cell vehicles. When used with a Vanner 80-Series Equalizer that has Model Based Battery Monitoring (MBBM), the converter optimizes 12/24 VDC battery charging using Vanner algorithms that continuously calculate the state of the battery’s health and charge. These products support Vanner’s Dashboard diagnostic software and CAN connectivity.

“Using our new SiC converter and our engineering implementation, electrical efficiency operates between 96-98%. This near 100% efficiency is especially important when heavy-duty zero-emission vehicles are looking for efficiency gains to extend their operating range,” said Alec Cook, VP of Engineering and CTO at Vanner.

Source: Vanner



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Ford to launch plug-in hybrid Ranger pickup in Europe


Ford will offer customers a plug-in hybrid version of its Ranger mid-size pickup in Europe. Production is to start in late 2024, and deliveries to customers are expected to begin in early 2025.

The Ranger Plug-in Hybrid sports a 2.3-litre EcoBoost petrol engine along with an electric motor, and boasts an electric range of over 45 km (28 miles). Electric drive capability is a handy feature in Europe, where a growing number of towns and cities are implementing low-emission zones.

The maximum braked towing capacity of the Ranger Plug-In Hybrid is expected to be 3,500 kg, the same as the rest of the Ranger line-up. The truck will offer 4WD off-road capability, 5 selectable drive modes and various driver assist features. Pro Power Onboard enables drivers to use power tools and appliances on a work site or remote camp site by plugging them into power outlets embedded in both the cargo bed and the cabin.

“Our customers want electrified vehicles that deliver strong performance and affordable cost of ownership without compromising what they love about their truck,” said Hans Schep, General Manager, Ford Pro Europe. “The Ranger Plug-in Hybrid is a best-of-both-worlds solution for work, play and family—offering customers zero-tailpipe emission EV driving for short trips, or hybrid performance that delivers incredible off-road, payload and towing capabilities. And, with Pro Power Onboard for the first time, Ranger owners can power their work sites and camp sites easily.”

Ironically, Ford’s announcement of the new plug-in pickup came at the same time that UK Prime Minister Rishi Sunak announced plans to renege on his country’s pledge to end new petrol and diesel car sales in 2030—a policy that Ford and other automakers have been counting on as they plan future production.

Ford UK chair Lisa Brankin noted that her company is investing some £430 million in its UK facilities, and called the 2030 target “a vital catalyst to accelerate Ford into a cleaner future.” Brankin said business “needs three things from the UK government: ambition, commitment and consistency. A relaxation of 2030 would undermine all three.”

Source: Ford



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MAHLE develops a new bionic battery cooling plate


German automotive parts supplier MAHLE has developed a new bionic battery cooling plate with cooling channels modeled on shapes encountered in nature (i.e. coral) that cause the coolant to flow differently than conventional flow-through solutions.

MAHLE’s bionic structure improves the thermodynamic performance and structural-mechanical properties of the cooling plate, says the company. Also, the design increases cooling performance by 10% and reduces pressure loss by 20%, resulting in increased battery efficiency and quicker charging.

MAHLE also says it has reduced the amount of material used for the plate by up to 15%.

The company’s bionic plate controls the flow rate of the coolant according to demand, especially in the case of small temperature differences between battery cells and coolant. According to MAHLE, the temperature range of the battery cooled by the new bionic plate can be reduced by 50%, and peak temperatures, in particular, can be significantly lowered. The bionic structure also offers design advantages, such as greater rigidity, which makes it possible to use the battery cooling plate with lower material thicknesses.

“With our new battery cooling plate, we are breaking away from technical geometries and are instead using natural structures, such as the coral shape, which improves our cooling technology and provides advantages in structural stability,” said Dr. Uli Christian Blessing, Head of Global Development Thermal Management at MAHLE.

Source: MAHLE



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Electric taxis in Austria use automated charging system as the country phases out fossil-fueled taxis


Taxis in Austria are going electric. Starting in 2025, only emission-free taxis will be allowed (unlike some countries currently in the news, Austria has shown no signs of reneging on this pledge).

Automated EV charging can greatly facilitate taxi electrification, as e-taxis can charge automatically while waiting at taxi stands. The eTaxi Austria project has been testing Matrix Charging technology, developed by the Austrian company Easelink. In Vienna, some 8 taxi stands and 56 vehicles are now equipped with the technology. In Graz, 2 stands and 10 vehicles are getting wired up.

Easelink’s Matrix Charging relies on a connector on the underbody of the EV, and a charging pad at the taxi stand. Drivers can initiate charging with the push of a button, without leaving the vehicle. Currently, Austria’s electric taxi drivers are using the system with the VW ID.4 and the Hyundai Ioniq 5.

Local utilities Wien Energie and Energie Graz installed and operate the charging systems, and will be supplying 100% green electricity for charging the electric taxis. The system delivers up to 11 kW of AC power, which is distributed among the vehicles based on demand, by means of an intelligent load management system.

Easelink’s latest generation of ground pads incorporates electronic switching components, so there’s no need for above-ground switch cabinets at the taxi stands. “The unobtrusive charging pads embedded in the ground pose no barriers to movement,” said Vienna City Councilor Peter Hanke.

“The eTaxi Austria project is the world’s largest e-mobility project focused on automated charging,” said Hermann Stockinger, founder and CEO of Easelink. “Together with over 30 partners, we are overcoming the central hurdle to barrier-free charging in the urban environment.”

Source: Easelink



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EVgo receives first shipment of Buy America 350 kW DC fast chargers from Delta Electronics


Public fast charging network EVgo has received the first shipment of 350 kW fast chargers from Delta Electronics that are manufactured according to Build America, Buy America Act (BABA) standards. Delivered from Delta Electronics’ recently opened factory in Plano, Texas, this first shipment marks a milestone in developing the domestic supply chain needed to unlock funding through the National Electric Vehicle Infrastructure (NEVI) Formula Program.

Delta has delivered 10 chargers to date, and EVgo expects to receive additional 350 kW BABA-compliant chargers from Delta Electronics later this year.

The Bipartisan Infrastructure Law includes $7.5 billion in funding for EV charging stations. Delta’s equipment is manufactured to meet BABA standards issued by the Federal Highway Administration, which is required for any charging stations that receive federal funding. To date, EVgo and its eXtend partners have been selected for millions in preliminary awards from NEVI programs in Ohio, Colorado and Pennsylvania.

“As states award their initial round of NEVI funding, the arrival of EVgo’s first batch of BABA fast chargers—with incredible speed for onshoring—signals both a tremendous moment for domestic charger manufacturing and for additional public funding opportunities as more states announce their awards,” said Dennis Kish, COO of EVgo. “EVgo and Delta share a commitment to developing a resilient supply chain here in America, and this collaboration showcases the companies’ capability to deliver the high-quality, high-power fast chargers we need to meet the growing demand for fast charging across the country.”

In addition to its work to onshore its supply chain, EVgo is also actively working with its suppliers to help ensure future chargers will integrate Tesla’s NACS system, which is currently making its way through standards bodies.

Source: EVgo



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Wednesday, September 20, 2023

Webinar: Multiscale design of a battery thermal management system


What if you could manage battery pack temperature, prevent quick degradation and thermal runaway, while reducing the risk of lithium plating and improving fast-charging capabilities for low temperatures?

Creating a reliable system for managing the temperature of a battery pack is not an easy task. Using multi-level modeling and multiphysics simulations, Siemens offers an integrated solution for designing an energy-efficient battery thermal management system.

In this 60-minute webinar, Lionel Broglia and Aziz Abdellahi from Simcenter explain how to increase range by designing and optimizing the battery thermal management systems deploying a multiscale digital twin. The experts will explain how to link vehicle, pack and cell scales, speed up development time, reduce the number of prototypes, and anticipate the impact of design changes.

Key topics and takeaways:

  • Gain insights into deploying a multiscale digital twin
  • Identify the trade-offs between battery life, fast-charge capabilities, and range
  • Evaluate the safety of battery packs under thermal runaway scenarios

Join the webinar and ask your questions. Our experts will answer them live.

This webinar will be hosted by CHARGED on Thursday, October 26th at 11 AM EDT.

Register now. It’s free!



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Download the Battery Management System Resource Kit


Within an electric vehicle (EV) battery system, the battery management system (BMS) is the electronic system that manages the battery pack and the cells. The BMS is critical for optimum battery performance and safety which means it must operate with a high degree of accuracy and reliability. It must be able to withstand the harsh environment it resides in yet remain compact, lightweight, and limit any additional bulk to the overall battery pack. 

In considering the above, we would love to share more information about the BMS in EVs and how connector systems play an integral role in achieving the requirements needed for the BMS. To learn more, register now to access our BMS Resource Kit. 

The BMS Resource Kit Includes:

  • Application Guide: Signal and Power Connector Systems for EV Batteries
  • Brochure: Connectivity Solutions for Battery Management
  • E-Mobility Interactive Illustration
  • Battery Interactive Illustration
  • White Paper: Automotive Connector Strategies and Solutions for Space Reduction
  • White Paper: Battery Connectivity, Management and Protection


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Frustration with delays in implementing the Megawatt Charging System standard


The Charging Interface Initiative (CharIN), an industry alliance with over 320 members, is working to establish a new Megawatt Charging System (MCS) for heavy-duty electric vehicles. The new standard is expected to be operational as early as 2024, but some in the industry are complaining about delays, and putting pressure on CharIN to accelerate the timeline for bringing MCS to market.

MCS is widely seen as a critical enabling technology for highway charging of Class 6 and above electric vehicles. It offers up to 1,250 V, 3,000 A and a power level of up to 3.75 MW—enough to allow a heavy-duty vehicle to top up within the mandated 45-minute break time for drivers.

Electric truck expert Rustam Kocher told Charged in a recent interview: “MCS should put a bullet in hydrogen, because the only thing that they have going for them is speed of refueling. With MCS it’s the same speed. In fact, it might be faster, so hydrogen can go pound salt.”

MCS has now reached the prototype phase, but as Ciaran Donnelly writes in EV in Focus, the final approval from slow-moving standards bodies could take a while yet, and some industry players are getting antsy.

Tesla was a member of the CharIN MCS taskforce, but decided to go ahead with its North American Charging Standard (NACS), which can support 1 MW charging, for its electric Semi. Nxu, a manufacturer of battery cells and packs, left CharIN in July, citing its impatience with the organization’s timeline, and began testing its own proprietary heavy-duty charging solution.

CharIN unveiled and demonstrated MCS last June, and members are rolling out design prototypes. “We are now in the prototype phase, so in principle it is ready,” CharIN Chairman Claas Bracklo told EV in Focus. “We have 17 charger manufacturers currently building prototypes. We have 18 truck manufacturers building those prototypes. We have 13 cable connector companies and 10 charge point operators.”

The main challenge now seems to be the formal standardization process, which requires input from all interested parties, some of whom have competing interests. “The challenge is to agree and to align this big community,” says Bracklo. “There are sometimes different interests of parties and somebody has an advantage by slowing that down.”

However, while the standardization process may seem frustratingly slow, cross-industry collaboration shortens time to market in the long run, says Bracklo. “If you start from scratch, it costs you 8-10 years. We have sorted out all of the complications, and the standardization is just the final step to make a formal standard out of that. Nevertheless, all these procedures, they will somehow lead us into the last part of 2024.”

Source: EV in Focus



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Andersen EV doubles production capacity of home chargers


To meet growing demand, UK home charging point producer Andersen EV is increasing the production capacity of its A2 unit by a factor of two.

In an upgrade to the headquarters and production site of Andersen EV and its parent company, EVIOS, in Stewartby, Bedfordshire, Andersen EV is doubling the footprint of its factory. The upgrade includes installing advanced manufacturing equipment and recruiting to fill additional positions in R&D, installation, customer service and manufacturing.

“Order books for the A2 continue to grow, and we’re delighted to be able to take very tangible steps that now mean anyone ordering an Andersen A2 will have their unit dispatched the next working day,” said CEO David Martell.

The project is scheduled for completion by August 31. It is part of a £1.5-million investment by EVIOS.

Source: Andersen



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Future-proofing battery testing for evolving EV technologies (Webinar)


As the EV market continues to grow exponentially, the need for new and innovative battery technologies becomes increasingly evident. To meet the demand for higher power, improved efficiency, and extended vehicle range, EV batteries are evolving rapidly, including advancements in solid-state, zinc-air, graphene batteries, and more.

In this webinar at the Fall Virtual Conference on EV Engineering, presented by EA Elektro-Automatik, we will explore the challenges posed by the ever-changing landscape of EV battery technology and the critical role of comprehensive testing systems in ensuring the success of emerging battery innovations.

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Reserve your spot—it’s free!


Other sessions at our Fall Virtual Conference include:

Wire Bonding & Smart Welding Battery Modules for Prototype & Production

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In this session—presented by Hesse Customers Solutions—we will explore how, together with its partners Acculon Energy and Calogy Solutions, the company provides a wire bond and/or smart weld service to those companies who need battery modules made for prototype or production purposes.

Reserve your spot—it’s free!


See the full session list for the Fall Virtual Conference on EV Engineering here.

Broadcast live on October 2-5, 2023, the conference content will span the EV engineering supply chain and ecosystem, including motor and power electronics design and manufacturing, cell development, battery systems, testing, powertrains, thermal management, circuit protection, wire and cable, EMI/EMC and more.



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Shenzhen Kehua unveils high-efficiency 40 kW SiC charging module

Power electronics manufacturer Shenzhen Kehua has developed a 40 kW silicon carbide high-efficiency, low-noise charging module, which is i...