Australian mining company Renascor Resources has completed equipment trials for its planned purified spherical graphite (PSG) manufacturing facility in South Australia.
The trials produced graphite of the quality required for lithium-ion battery anodes across all targeted product specifications up to 99.99% carbon—compared with the anode industry standard of 99.95% carbon. The tests were also below industry impurity standards. This further validated Renascor’s hydrofluoric (HF)-free purification process and provided detailed equipment specifications for the facility, according to the company. The company has commenced engineering for the demonstration facility, which is scheduled to start commissioning in Q2 2025.
Renascor is developing vertically integrated battery anode material (BAM) production in South Australia comprising a graphite mining and processing operation and a downstream BAM facility that will refine graphite concentrates into PSG for export to lithium-ion battery anode manufacturers.
“Renascor’s HF-free purification technology has the potential to deliver a globally competitive PSG operation and advance Renascor towards its goal of becoming a long-term producer of high-quality graphite products to the lithium-ion battery sector,” said David Christensen, Renascor’s Managing Director.
As a leading provider of advanced materials for EV battery systems, Henkel has taken a pioneering role in utilizing advanced modelling and simulation to develop materials for its e-mobility portfolio. In this webinar, we will highlight the importance of simulation in improving materials and achieving better designs for innovative EV battery systems. We will explore Henkel’s range of solutions for creating safe, sustainable, and high-performing battery designs, with real-life examples that showcase improvements in structure, thermal management, and safety.
Key takeaways:
The contribution of Henkel’s advanced modeling, simulation, and testing in the early design phase of battery systems
Validating the performance of multi-functional materials in the battery systems before physical testing via simulation
The aid of simulation to the enhancement of the safety aspects in battery systems
This webinar will be hosted by CHARGED on Wednesday, October 30th, at 11 am US EDT.
Finland-based Proventia, which manufactures emissions-control systems for off-road machinery, has signed a letter of intent to develop lithium-iron-phosphate (LFP) battery packs with Norwegian battery cell manufacturer Morrow Batteries for heavy-duty machinery.
Morrow has opened its first factory and expects to produce commercial batteries by the end of the year. The Morrow Cell Factory’s annual production capacity is 1 GWh. The company plans to build three modules at the site, each with a planned annual production capacity of 14 GWh.
Proventia will work with Morrow to develop systems for the off-road mobile machine market. The companies aim to supply pilot systems to customers during 2025 and start serial deliveries in 2026.
Proventia currently has battery systems based on lithium-titanate-oxide (LTO) technology and plans to expand its portfolio by adding LFP and lithium-nickel-manganese-oxide (LNMO-X) technologies in the future, all of which are suitable for the harsh conditions faced by heavy machinery.
“Morrow has demonstrated their technical expertise for battery cells and systems and a strong track record of ramping up development and production. Our future roadmap includes advanced cell technologies beyond LFP technology. The LFP packs we are developing today around the Morrow LFP cells will also be available with LNMO-X chemistry,” said Proventia CEO Jari Lotvonen.
EverCharge, a provider of large-scale EV charging solutions, has introduced a new approach to improving the efficiency of EV fleet charging operations: real-time visual alerts, including mobile alerts and in-field LED lights.
As the company explains, fleet managers are often not immediately aware when a vehicle has finished charging, so dwell times may substantially exceed the time needed to charge a vehicle. Dashboard-based software solutions and apps may indicate the state of charge for each vehicle, but they require extra steps by fleet managers or vehicle attendants to view vehicle status. Also, when managing a larger fleet or multiple locations, manual checks can introduce more human errors into the process, unnecessarily leaving fully charged vehicles on charging stations.
EverCharge’s visual and audio smart alerts are designed to let fleet operators know immediately where and when they need to take action, helping them to get the most out of their existing charging infrastructure. These real-time notifications seamlessly fit into fleet attendants’ day-to-day operations, and can help to eliminate language and technical barriers.
The smart alerts are powered by EverCharge’s patented SmartPower platform. While SmartPower works behind the scenes to perform load balancing, the in-field LED lights provide an immediate visual cue that a vehicle has finished charging, even at a distance.
Early adoption data from an EverCharge fleet customer indicated a 41% charging efficiency increase through the in-field LED light installation within a year of installation.
“This new approach will provide our customers, especially those who manage large fleets, with the ability to significantly scale their efficiency,” said Jeffrey Kinsey, VP of Engineering at EverCharge. “With these new real-time smart alerts, fleet and site managers won’t have to worry about the extra step of signing into an app each time they need a charging update. The notifications will simply be available to them through mobile alerts, and visually with the in-field LED lights, so they can take action right away.”
The US Department of Transportation (DOT)’s Federal Highway Administration (FHWA), along with the Joint Office of Energy and Transportation, has issued a Request for Information (RFI) from stakeholders about EV charging technologies and the infrastructure needs for medium- and heavy-duty vehicles.
The RFI supports the Biden Administration’s aim to build a national EV charging network. The administration is seeking input on how new technologies and innovations are shaping the needs of EV manufacturers, fleet operators, truck drivers, charging station operators and electric utilities.
The RFI identifies four areas: unique EV charger and station needs; vehicle charging patterns; charging technology and standardization; and workforce, supply chain and manufacturing to support charging of vehicle classes four through eight. This includes delivery vans, school buses, semi-tractor trucks, fire trucks, dump trucks, and tour buses. The deadline for comments is November 12, 2024.
The information submitted will inform how the federal government—including the EPA and other agencies—can support the development and build-out of a national EV charging network and set federal standards. This follows the release of the National Zero-Emission Freight Corridor Strategy earlier this year.
“Getting information from the industry and communities impacted by future regulations is essential to helping the federal government understand how to support investments in vehicles like buses, trucks, vans and larger vehicles,” said Acting Federal Highway Administrator Kristin White.
EP North America, a lithium-ion-focused material handling equipment provider, has introduced two new forklifts, which are now available through its dealer network.
The CPD45F8/50F8 is an IPX4-rated, pneumatic forklift designed for outdoor use to suit applications up to 10,000 lbs. The CPD45F8/50F8 has an integrated EP Energy 80 V lithium-ion battery that requires zero maintenance, according to the company.
The EFLA251 is a Class I forklift engineered to provide a direct alternative in use and cost to a Class IV LP equivalent. It features a lifting capacity of 5,000 lbs and an EP Energy 80 V lithium-ion battery.
EP has added demo units to its fleet.
“Whether leading occasional or multi-shift operations, these lithium-ion powered solutions provide the value, quality and dependability that we believe our dealer network and their customers have been looking for,” said Jason Bratton, General Manager, EP North America.
Throughout the history of design, the Italian approach has been consistently characterized by a specific style, one engrained in the DNA of the artisans and their innovations. Indeed, the artistry of Italian design derives directly from the ateliers that existed during the Renaissance, and it is therefore not surprising that Italian designers continue to work with a creative and anthropological attitude that allows them to create projects that are fundamentally artistic as well as emotionally charged.
The two electric vehicles that AEHRA, Italy’s new EV manufacturer, just introduced—the Impeto, an SUV, and the Estasi, a sedan—are about as emotionally charged in design as one could imagine while also requiring charging for their means of locomotion.
The Impeto, the automaker said, derives its name from the word “impetus,” while the Estasi “is named for the emotion ‘ectasis’, an intense rapture deriving from the contemplation of an object’s beauty.”
AEHRA plans to build a manufacturing campus at Mosciano Sant’Angelo in Abruzzo at a cost of €1.2 billion ($1.3 billion). The Abruzzo plant will create an estimated 540 new jobs as well as an additional 110 jobs in Milan. The EV maker plans to start production of its first two models by mid-2026 before scaling up to 25,000 units of each model annually.
“The Italian government’s potential endorsement of AEHRA’s funding application underlines the national strategic importance the brand will play in delivering sustainability at scale,” the company said.
EMP Metals, a Canadian lithium exploration and development company, is conducting a direct lithium extraction (DLE) pilot at its facility in Saskatchewan.
The facility has a DLE pilot skid from UK engineering technology firm Koch Technology Solutions (KTS), while Canadian lithium refining systems supplier Saltworks Technologies provided pre- and post-DLE systems and concentrate, refine and convert (CRC) technology to produce battery-grade lithium carbonate.
The geological brine was processed through the KTS Li-Pro pilot over 75 days, demonstrating a lithium recovery of greater than 97% and impurity rejection of greater than 99%. The DLE eluate has been delivered to Saltworks for processing through its Pilot 10 lithium refinery to convert it into a battery-grade lithium carbonate for delivery to offtake customers.
“The site pilot produced lithium concentrations in the DLE eluate exceeding 2,000 mg/L with a Li:TDS ratio greater than 0.1, almost non-detectable organics, low silica and steady performance improvements as the system was remotely optimized,” said Megan Low, VP of Lithium Process Solutions at Saltworks. “Li:TDS ratio is a key performance indicator. A ratio of 0.1 or higher is among top-performing DLE systems and is reflective of the high quality and clean Saskatchewan brine processed. This Li:TDS ratio will allow efficient downstream refining to battery-grade materials.”
This 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 of the live sessions will be recorded and available to view after the broadcasts. The recorded videos can be accessed on each session’s registration page.
Tuesday, September 17th Session Topics:
9:15 am EDT Application Specific MOSFETs For Automotive Power Join Us
9:30 am EDT Innovative Testing Solutions For Advanced Energy Storage and Driver Assistance Systems Join Us
10:15 am EDT Ultrasonic Welding Application In EVs Join Us
10:30 am EDT Repurpose Or Recycle: Test Methods For Evaluating Batteries After Their First Life Join Us
11:00 am EDT Megawatt Charging And Its Implications: Revolutionizing Commercial EVs
Electric vehicles are simpler than legacy combustion engine vehicles, and generally require less service. However, when a breakdown does occur, repair costs can be significant, so some buyers choose to purchase an extended warranty or service contract that offers coverage beyond that provided by the manufacturer’s warranty.
DOWC offers a service contract that’s designed specifically for EVs. The company’s eVSC product offers comprehensive inclusionary coverage of all major systems and components, including the driveline, drivetrain, EV components, gaskets, cooling systems, brakes, steering, suspension and more.
So far, that sounds like the sort of extended warranty package that you can buy for any new vehicle, whether it’s a cutting-edge EV or a vintage gas-burner. However, DOWC also offers protection for a very important EV accessory that ICE drivers don’t have: charging infrastructure.
One of the most popular benefits of driving electric is never having to go to a gas station, so the vast majority of EV buyers who have a dedicated parking spot for their vehicle are going to purchase and install a moe charging station. These are typically highly reliable, but defects and malfunctions—and sometimes, unexpected installation costs—do occur. DOWC offers the option of adding charging hardware and installation to its eVSC product.
DOWC customers have the option of adding an eVSC welcome package to their contract, which includes a Level 2 home charger and a credit towards professional charger installation (up to $750). This option offers some additional peace of mind, especially for first-time EV buyers, who may not wish to delve into the complexities of selecting and installing a home charger.
The Ports of Jersey has entered a partnership with local on-demand electric transport service EVie to provide transport to and from both the airport and the Elizabeth Terminal harbor.
The scheme complements a network of EVie vehicles and allocated parking spaces across the island of Jersey. There are now 10 allocated EVie parking spaces at the airport and four at Elizabeth Terminal. Customers check the EVie app for cars and available spaces, book a car, drive to the location and park it in one of the spaces.
“Collaborating with EVie to offer our customers sustainable choices will make travelling to and from the airport and harbor more convenient. We hope this will make a real difference for Islanders and visitors, and the next stage will be to extend the scheme to our marinas and historic harbors,” said Sophie Roffe, Ports of Jersey’s Head of Sustainability and Community Value.
Paris-based global aluminum products manufacturer Constellium has announced that its ALuminium Intensive Vehicle Enclosures (ALIVE) collaborative research project has achieved weight savings in its structural aluminum EV battery enclosures.
The project reduced the weight of the enclosures by between 12% and 35% compared to existing aluminium and steel OEM designs, while meeting or exceeding performance targets.
The £15-million project began in 2020 and was half-funded by government subsidies through the UK’s Advanced Propulsion Center. The lead partner was Constellium’s University Technology Center (UTC) at Brunel University London. The other industrial partners were BMW, EXPERT Technologies Group, Innoval Technology, Powdertech and Volvo. Two university technology partners were Brunel University London and the University of Warwick.
The goal of developing novel high-performance, lightweight and cost-efficient aluminium battery enclosure designs for the project’s OEM partners, BMW and Volvo, was pursued by investigating various joining and forming technologies in combination with Constellium’s high-strength alloys—Constellium HSA6 and Constellium HCA6—and by creating a full-scale battery enclosure prototyping line.
Several prototype enclosures were built that have passed rigorous testing for crash/side impact, bottom intrusion, acceleration, shock, vibration and leaks. Constellium researchers are now adapting the project’s design philosophies to other enclosure types, including chest battery packs for trucks and SUVs.
US-based Wright Electric, a manufacturer of ultra-lightweight motors, generators and batteries for aerospace and military applications, has been awarded the US Air Force AFWERX SBIR Phase 1 contract to develop Wright’s rechargeable thermal batteries for use in multi-rotor unmanned aerial vehicles.
Wright, in conjunction with NASA, Advanced Research Projects Agency-Energy (ARPA-E) and the Department of Defense (DoD), has been developing ultra-lightweight motors and batteries for aircraft and also identifying industrial and military-related applications for them.
Under the contract, Wright will leverage additive manufacturing to quickly produce small volumes of rechargeable batteries that can take the place of the legacy single-use, high-operating-temperature thermal batteries that are widely used in a range of military equipment.
“Instead of advancing a completely new battery chemistry, our aim is to develop a process that will let us do limited production runs of exotic batteries at a reasonable cost,” said Aaron Rowe, Engineering Manager, Batteries, Wright Electric. “Thanks to support from the Air Force, we can take our first steps with a new program to deliver batteries that are extremely compact and capable of ultra-high discharge rates.”
Industry groups that represent convenience stores, truck stops, travel centers and rest areas in the US want EV drivers to come to them for their recharging needs, just as drivers of ICE vehicles have patronized them for their refueling needs.
Three industry groups—the National Association of Truck Stop Owners (NATSO), which represents travel centers and truck stops; the Society of Independent Gasoline Marketers of America (SIGMA), a trade association that represents independent fuel marketers and chain retailers; and the National Association of Convenience Stores (NACS)—have all voiced their opposition to a bill recently introduced in Congress, the Recharge your Electric Car on the Highway to Alleviate Range Gaps Effectively Act, or RECHARGE Act.
If passed into law and signed by the president, the bill would amend current federal law to remove a prohibition on automotive services at rest areas, thereby allowing companies not represented by these three trade groups to install charging stations at such sites.
The bill would strike existing language in the Congestion Mitigation and Air Quality Improvement Program, Section 149(c)(2) of Title 23, United States Code, which provides that “such stations may not be established or supported where commercial establishments serving motor vehicle users are prohibited by section 111 of Title 23, United States Code.” This language has kept filling stations from operating in highway rest areas.
These are distinct from service plazas or service areas, which offer filling stations, convenience stores and, occasionally, restaurants.
The three organizations have argued that the RECHARGE Act poses a risk to the $5-billion National Electric Vehicle Infrastructure Grant Program under the Infrastructure Investment and Jobs Act and, by extension, to their members.
“Truck stops, travel centers, convenience stores and fuel marketers are making investments in EV charging stations,” the three said in a statement.
David Fialkov, Executive Vice President of Government Affairs for NATSO and SIGMA, sees the bill as “a misguided approach to electrification that ultimately will limit the development of a safe and reliable EV charging network,” pointing out that the industries his groups represent are willing to invest in EV charging.
Fialkov said that “allowing EV charging at rest areas will keep the private sector from installing EV chargers at today’s refueling locations,” citing a 1960 federal law that has prohibited the sale of automotive services and food at state-operated rest areas “to encourage competition between private businesses located at the Interstate exit interchanges.”
Greenlane, an EV charging joint venture owned by Daimler Truck, NextEra Energy Resources and investment firm BlackRock, has secured a $15-million grant from the South Coast Air Quality Management District (SCAQMD). The grant will allow Greenlane to accelerate the development of its first commercial EV charging corridor along Interstate 15.
SCAQMD’s funding will be used for site design, engineering and charging infrastructure construction at Greenlane’s flagship charging site in Colton, near the intersection of Interstates 215 and 10 in California. The Colton site is expected to be commissioned by the end of 2024. When completed, it will include more than 60 chargers for heavy-, medium- and light-duty EVs. Some 41 charging pedestals and 53 connectors will be funded by the SCAQMD grant.
Greenlane aims to develop a network of commercial charging infrastructure locations across the US and Canada. The charging sites will also serve passenger EVs and light-duty fleet customers.
“Greenlane is clearly defining a path towards a more sustainable future not only for the transportation industry but also for residents living in San Bernardino County, who are subject to higher levels of air pollution,” said Larry McCallon, SCAQMD Governing Board Member. “Freight transportation from the goods movement corridor has been a major source of air pollution in our region.”
“By establishing corridors and deploying a nationwide network of public charging stations, we’re not only meeting the pressing demand for accessible infrastructure for commercial vehicles but also pioneering a transformative model for the future of commercial EV charging,” said Greenlane CEO Patrick Macdonald-King.
Paris-based EV charging infrastructure provider ChargeGuru x Zeplug has partnered with global EV charging management platform provider AMPECO, headquartered in Bulgaria, to power its network of charging stations in France, Spain, Portugal, Belgium, Germany, Italy, the UK and Ireland.
ChargeGuru and Zeplug merged in 2023 to combine the two companies’ strengths: ChargeGuru’s network of local installation electricians and Zeplug’s charging stations designed for multifamily properties, shared office buildings and fleets. Plans call for the combined company to deploy 100,000 charge points by 2025 that will use the AMPECO platform.
“The adoption of AMPECO’s platform marks a new chapter,” said Gilles Gomis, ChargeGuru x Zeplug co-founder. “This partnership empowers us to deliver tailored solutions that meet the specific needs of our customers across different markets, all while driving forward our e-mobility adoption goals.”
New research from Chalmers University of Technology shows why lithium metal batteries have short lifespans and how to extend them by creating the metal electrode directly in the battery cell.
Lithium-ion batteries with metal electrodes instead of graphite electrodes are gaining attention. However, metal electrodes are reactive, making it hard to produce a long-lasting cell. A research group at the Department of Physics at Chalmers has used 3D X-rays to monitor how the lithium in a lithium metal battery behaves in real time during operation. These experiments revealed that lithium forms uneven structures during charging and discharging, affecting its stability.
The results show a simple way to avoid the formation of a surface layer on the reactive electrodes, which damages batteries over time. If the metal electrode is created inside the battery, the metal never has the opportunity to react with impurities outside the battery, and develops a better and more stable surface layer.
“We create our electrode inside the battery through a process called electroplating. This allows us to avoid the reactive metal reacting with the environment, which is an advantage as we get a more predictable and stable electrode,” said Josef Rizell, doctoral student at the Chalmers Department of Physics.
Volvo Trucks plans to launch a long-range variant of its FH Electric truck, with a range of up to 600 km (373 miles)—about twice the maximum range of the current-generation FH Electric. (North American VNR Electric models offer a range of up to 275 miles.)
The new model is slated to go on salw in the second half of 2025.
The extended range is mainly enabled by the use of an e-axle in place of the multiple motors and I-Shift gearbox used in the current FH and VNR models, which frees up space for more battery capacity. (Volvo debuted a new e-axle concept at the IAA fair in Germany in 2022.) More efficient batteries and powertrain along with an improved battery management system also allowed Volvo’s designers to squeeze out a little more range.
Volvo Trucks says it has delivered more than 3,800 electric trucks to customers in 46 countries around the world.
“Our new electric flagship will be a great complement to our wide range of electric trucks and enable zero-exhaust emission transport also for longer distances. It will be a great solution for transport companies with a high annual mileage on their trucks and with a strong commitment to reduce CO2,” said Volvo Trucks President Roger Alm.
In this presentation, we will explore the cutting-edge advancements in energy storage systems, including batteries and fuel cells, which demand rigorous testing and certification throughout their development. Discover comprehensive solutions that range from precise measurement data recording to fully automated test procedures, ensuring reliability and efficiency in these new technologies.
Additionally, in this webinar presented by imc Test & Measurement, we will delve into the realm of Driver Assistance Systems (DAS), where the accuracy of real-time data is paramount. Learn about the integration of detailed measurement data from steering, wheels, speed, position, and driving dynamics, such as slip angle, to enhance simulation data. This combination of real-time and simulated data is crucial for the development of advanced DAS features like lane departure warnings.
Whether you’re involved in energy storage innovation or the advancement of driver assistance technologies, this webinar will provide you with the knowledge and tools to meet the emerging challenges and opportunities in these dynamic fields.
Other sessions at our Fall Virtual Conference include:
How to Prepare For Testing Challenges On More Powerful EV Batteries
As demand for advanced battery technologies grows, the need for efficient and safe battery testing systems becomes critical.
This webinar, presented by EA Elektro-Automatik and Tektronix, will explore the latest challenges in battery testing, including high utility costs, limited test capacity and ensuring safety during testing. We will discuss industry best practices for achieving maximum efficiency, flexibility and safety in battery testing, focusing on modular designs and regenerative power technologies.
Join us to learn how to reduce operating costs, improve uptime and meet future testing requirements, ensuring your battery testing processes are equipped for the evolving demands of the market.
Broadcast live on September 16-19, 2024, 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.
Energy management systems aren’t just for vehicle fleets anymore—as homeowners add EVs and/or solar panels to their electrical empires, it increasingly makes sense to have a comprehensive system to manage it all.
Intelligent power management company Eaton offers a suite of home energy management solutions for both retrofit and new construction projects, including smart breakers, microgrid interconnect devices and smart panels.
Now Eaton has launched its new AbleEdge home energy management system, which offers homeowners and installers “a comprehensive, quickly installed and fully integrated solution to simplify a safe energy transition.”
Eaton’s AbleEdge home energy management system is designed for interoperability with any residential energy storage and solar system in North America through open application programming interface (APIs) and multiple communication options for its microgrid interconnect device.
AbleEdge is designed to make it easier to install distributed energy resources (DERs), extend battery life and enable a seamless transition to backup power sources during grid outages.
The AbleEdge ecosystem includes:
AbleEdge smart breakers, which provide load management to help extend battery life;
The AbleEdge microgrid interconnect device, which enables a seamless transition from grid power to energy storage system, and can be retrofitted to existing Eaton meter breakers;
AbleEdge critical loads and combiner box panels, which feature flexible configurations designed to accommodate almost any installation and retrofit requirements.
“We’re providing flexible, cost-effective options to add solar and energy storage at home that minimize equipment and maximize functionality, without replacing your electric panels. We first delivered pioneering smart breakers to enable new levels of intelligence and scalability, and our AbleEdge ecosystem will transform new and existing Eaton home infrastructure,” said Paul Ryan, General Manager of Connected Solutions and EV Charging at Eaton. “And we’re working closely with the biggest names in home solar and energy storage to accelerate a more sustainable, electrified future.”
Much of the focus on electrifying commercial trucks has been on optimizing electric powertrains and solving challenges like battery capacity, maximum battery voltage, eAxles and safety considerations. Long haul trucks present significant challenges to electrification due to battery size & cost and charging infrastructure.
A quicker path to electrification is often for work trucks – commonly Class 5-8 vehicles that utilize hydraulics, pneumatics, vacuum, water pumps, etc. to perform vocational work off of the truck chassis.
Commercial work trucks have historically utilized mechanical Power Take Off units (PTOs) to transfer power from the diesel engine and transmission to operate hydraulic, water, vacuum pumps, pneumatic compressors, etc. An ePTO replaces the traditional mechanical PTO for electrified vehicles. ePTOs are a broad term and represent many implementations and form factors, which can be confusing, but the benefits include reduced engine runtime, lower emissions and fuel and maintenance savings.
During this webinar, you will learn more about:
The various types of ePTOs and the rationale when considering which ePTO to specify
The advantages of using ePTOs in vehicles with and without an ICE engine
Typical power requirements, safety issues, and integration considerations
Architecture considerations to maximize efficiency and battery power conservation
ION Storage Systems, a Maryland-based manufacturer of solid-state batteries (SSBs), has reached a milestone towards commercialization by achieving 800 cycles in its SSB cells.
ION cells cycle without compression or volume change, a key SSB adoption barrier. ION’s SSB requires no compression, swell budget, extensive cooling system or heavy fire barriers. In early 2024, ION announced the first anodeless SSB to achieve 125 cycles without pressure, commissioned its $30-million manufacturing facility, and received $20 million from ARPA-E for EV SSB development.
Applications for ION’s battery cells include EVs, consumer electronics, medical devices, grid storage, and aerospace and defense.
“It is unprecedented for an anodeless cell to reach this kind of cycle life without compression. ION has now produced a cell with performance that’s compelling to replace a huge portion of the lithium-ion market,” said ION’s CTO, Dr. Greg Hitz.
Electric Vehicle Supply Equipment (EVSE) refers to the infrastructure and components essential for charging electric vehicles (EVs). Often known as charging stations, charging docks, or simply chargers, EVSE provides power supplies to recharge electric vehicle batteries. This comprehensive system includes charging stations, connectors, cables, and control systems, all meticulously designed to deliver electricity safely and efficiently to EVs.
What are the Components of EV Supply Equipment?
From housings to connectors, let’s look at the essential elements that power EVSE.
Housing/Enclosure EVSE housings are designed in various configurations to meet diverse charging needs. Standalone boxes are commonly employed for home charging setups, offering a compact and user-friendly solution. Wall or pedestal-mounted enclosures provide flexibility for multi-family residential, workplace, and other public charging environments, ensuring accessibility and convenience. Towers, prevalent at public charging stations or commercial fleet depot locations, consolidate multiple charging points into a single structure, optimizing space and resources. These enclosures are typically constructed using durable materials such as weather-resistant plastics or metals, safeguarding essential EVSE components from environmental elements.
Firmware The firmware embedded within EVSE components serves as the brains behind the charging operation, enabling advanced functionalities and ensuring compatibility with a wide range of electric vehicles. This microcode governs various aspects of charging management, including initiating and terminating charging sessions, implementing cybersecurity measures to protect against unauthorized access or tampering, and facilitating communication between the EVSE and the vehicle’s onboard systems.
Connector/Plug EVSE connectors play a crucial role in facilitating the transfer of electrical power between the charging station and the electric vehicle. Different connector types are used for various charging levels and charging standards, ensuring compatibility and interoperability across different EV models and charging infrastructure.
Common connector standards include J1772 for Level 1 and Level 2 charging, offering widespread compatibility across EV models. The CCS connector supports AC Level 1 and Level 2, as well as Level 3 DC fast charging, with additional pins for enhanced functionality. CHAdeMO is predominantly used by Japanese manufacturers for DC fast charging applications. The NACS (J3400) connector enables Level 2 and Level 3 charging, allowing non-Tesla EV charging at Tesla stations equipped with this standardized connector type.
These connectors feature robust construction and standardized pin configurations to ensure secure and efficient power transmission during charging sessions. By supporting multiple connector types, EVSE maximizes accessibility and convenience for EV owners, regardless of their vehicle’s make or model.
The variety of connector types in EVSE stems from vehicle manufacturers’ diverse port connections on EVs. Stations with multiple cable options are often available to accommodate various connectors. Naturally, many EV owners carry adapters on their own for charging at different stations just in case.
Electronics The electronic components of EVSE play a critical role in managing charging sessions and ensuring efficient power delivery to electric vehicles. The main relay acts as a gateway, controlling the flow of electricity to the vehicle and safeguarding against overcharging or electrical faults. The control module orchestrates the charging process, communicating with the vehicle and monitoring battery health to optimize charging efficiency. A robust power supply ensures stable power output, while dedicated electrical circuits for each charging socket minimize the risk of circuit overload and ensure reliable performance.
Cables Cables in EVSE serve as conduits, transmitting power from the charging station to the vehicle. They come in flexible or permanently attached options, offering maneuverability or enhanced durability. Ideally, longer cables provide greater convenience, but NEC regulations limit cable length to 25 feet. However, if equipped with a cable management system integrated into the EVSE, the cord length can exceed this limit. These regulations ensure safety and compliance with industry standards for EV charging installations.
Network Connectivity
By integrating WiFi or cellular connectivity, EVSE can communicate with mobile apps or cloud-based charging management platforms, allowing users to remotely monitor and control charging sessions from anywhere. This connectivity enables features such as scheduling charging times to take advantage of off-peak electricity rates, receiving real-time charging status updates and notifications, and accessing historical charging data for analysis and optimization. Network-connected EVSE also enables fleet operators and charging station owners to remotely manage and monitor multiple charging stations, ensuring efficient operation and maintenance.
Common Features of EVSE
EVSE comes with a range of features designed to ensure efficient and safe charging for EVs.
Firstly, EVSE often incorporates smart charging capabilities, allowing users to monitor and control the charging process remotely. Smart EVSE systems enable features such as scheduling charging times, setting charging limits, and receiving notifications on charging status via mobile apps or online platforms. This not only enhances user convenience but also enables more efficient use of electricity, particularly during off-peak hours when energy costs may be lower.
Furthermore, safety features are paramount in EVSE design. EVSE systems include built-in features, such as breakaway cables, safety outlets, thermal sensors, and ground fault circuit interrupters, to protect against overcharging, overheating, short circuits, leakage current, and other potential electrical hazards. These safety mechanisms ensure that both the EV and the charging infrastructure remain secure during the charging process.
Finally, interoperability is a key consideration in EVSE design. Compatibility with different EV models and charging standards ensures that EV owners have access to charging infrastructure regardless of their vehicle type or manufacturer. Common charging connectors, such as the SAE J1772 or CCS (Combined Charging System), allow for seamless connection between EVs and the charging stations.
Overall, the features of EVSE contribute to a user-friendly, efficient, and safe charging experience for electric vehicle owners, supporting the transition to a more sustainable transportation ecosystem.
Level 1 Charger
Level 1 chargers operate on standard 120-volt AC household outlets, making them the most accessible, budget-friendly, and convenient charging option for EV owners as they use typical household outlets. These chargers typically provide a slower charging rate compared to higher-level chargers. Charging a regular electric vehicle (EV) for 8 hours at 120 volts can add about 40 miles of electric range.
These chargers are suitable for residential charging, allowing EV owners to plug their vehicles into standard electrical outlets in garages, driveways, or parking spaces overnight. They are ideal for individuals with limited daily driving needs or those who have ample time for charging.
Level 2 Charger
Level 2 chargers operate on 240 volts AC power, offering faster-charging rates than Level 1 chargers even though they adopt the same J17772 connector. These chargers require the installation of dedicated stand-alone charging equipment. Charging an electric vehicle (EV) for 8 hours with a Level 2 charger can add more or less 200 miles of electric range for a mid-size EV.
These types of chargers are commonly installed in residential settings for faster home charging (multi-family units) or in public charging stations, workplaces, hotels, commercial buildings, and parking facilities. They are suitable for EV owners with moderate to high daily driving distances or those who require quicker charging due to their significantly reduced charging times.
Level 3 Charger Level 3 chargers, also known as DC Fast Chargers or DCFCs, operate on high-voltage direct current (DC) power (480 volts), providing rapid charging capabilities for EVs. These chargers can deliver significantly higher charging rates compared to Level 1 and Level 2 chargers, enabling quick replenishment of EV batteries. With 30 minutes of charging using DC Fast chargers, it can add around 100 to 200 miles of electric range.
These chargers are primarily installed in public charging networks, highway rest areas, service stations, and commercial areas where fast charging is essential for long-distance travel or quick turnaround times.
DC fast charging options are substantially pricier, often requiring 10 to 20 times more investment than other chargers due to their complex components and higher power input requirements. That’s why they are recommended for EV owners undertaking frequent long-distance trips or commercial fleet operators requiring rapid charging for multiple vehicles.
How Does EVSE Work?
When you connect your electric vehicle to an EVSE, several steps occur to initiate charging.
Upon connection, the EVSE communicates with the EV to confirm its readiness for charging. This involves assessing the battery status, charging capability, and compatibility with communication protocols.
For AC charging, the EVSE transforms the alternating current (AC) from the power source into a direct current (DC) suitable for the EV’s battery. This conversion happens within the EVSE’s control circuitry, which typically includes components like rectifiers, transformers, and voltage regulators. Subsequently, the EVSE delivers the converted DC power to the EV’s onboard charger.
On the other hand, DC fast charging skips the EV’s onboard charger entirely. Instead, the EVSE provides high-voltage DC power directly to the EV’s battery, leading to significantly shorter charging times. This requires specialized DC fast charging stations with robust power output capabilities.
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The Stockport, UK, outlet of France-headquartered sporting goods retailer Decathlon is opening a new 15-bay ultra-rapid EV charging hub, installed by UK charging network Be.EV.
Located in the town of Stockport, which is part of Greater Manchester, the site receives up to 20,000 visitors per week, and is minutes from the busy M60 motorway.
Decathlon celebrated the opening of the site with promotional offers and test drives of electric bikes, Octopus EVs and a Porsche Taycan.
The new chargers have a capacity of up to 150 kW and are capable of adding up to 165 miles of range in a 20-minute stop, which closely matches Decathlon’s customer dwell time of about 30 minutes.
“As more and more people choose to drive EVs, they’ll naturally gravitate to destinations where they can conveniently charge their car whilst shopping,” said Asif Ghafoor, CEO and founder of Be.EV.
Researchers at the Qingdao Institute of Bioenergy and Bioprocess Technology (QIBEBT) of the Chinese Academy of Sciences, along with collaborators from international institutions, have introduced a cathode homogenization strategy for all-solid-state lithium batteries (ASLBs).
Researchers have developed a solution: a cathode homogenization strategy utilizing a zero-strain material, Li1.75Ti2(Ge0.25P0.75S3.8Se0.2)3, or (LTG0.25PSSe0.2). This material’s combined ionic and electronic conductivity ensures efficient charge transmission during (dis)charging without conductive additions.
The LTG0.25PSSe0.2 material has shown a specific capacity of 250 mAh g–1 and minimal volume change of just 1.2%. A homogeneous cathode made entirely of LTG0.25PSSe0.2 enables room-temperature ASLBs to achieve over 20,000 cycles of stable operation and a specific energy of 390 Wh kg−1 at the cell level. The team plans to further explore the scalability of the material and its integration into practical battery systems.
“Our cathode homogenization strategy challenges the conventional heterogeneous cathode design,” said Dr. CUI Longfei, co-first author of the study, from the Solid Energy System Technology Center (SERGY) at QIBEBT. “By eliminating the need for inactive additives, we enhance energy density and extend the battery’s cycle life.”
Measurement and control specialist Yokogawa Electric will release a new online sheet thickness gauge—the OpreX Battery Web Gauge ES-5—as part of the OpreX Quality Control System family, in January 2025.
Since the release of its first online thickness gauge for sheet manufacturing equipment in 1962, Yokogawa has been delivering ever-newer versions of these products, which are used in final processes on production lines to continuously measure and control thickness, weight and other characteristics of sheet materials such as paper and film. Among these products is the WEBFREX3ES, which was developed for use in the production of electrode sheets for lithium-ion and other battery types, is used by major battery manufacturers.
The OpreX Battery Web Gauge ES-5 was developed to help battery manufacturers reduce CO2 emissions from their production processes and improve productivity, while retaining all the features found in the WEBFREX3ES. The box-type frame used in the new ES-5 reduces power consumption by over 50%, weighs 75% less, and reduces air consumption volume by 90% in comparison to the WEBFREX3ES.
The ES-5 features a 3-second scanning speed for the 1,500 mm scan width, achieves high-density measurement of up to 1,600 points widthwise, and has a minimum 5 mm slit width resolution.
The ES-5 is used with the OpreX Collaborative Information Server, which collects data from plant equipment and systems to ensure that an even coating is applied to electrode sheets—an important determinant of battery performance and quality.
“Given the movement towards electric vehicles, we have developed this online thickness gauge for battery electrode sheets that uses the Collaborative Information Server as its system platform,” said Yokogawa Electric VP Hiroshi Tanoguchi. “Development was undertaken based on the system-of-systems approach,a in which a collection of independently operated and managed systems connect to form a larger system, and the result is a product that saves energy and enhances quality, health, safety and environment.”
General Motors is merging its BrightDrop division, which designs and manufactures light electric commercial vehicles, into Chevrolet, in order to leverage the latter’s sales and service network.
BrightDrop was founded by GM in 2021. Chevrolet was founded 112 years ago in 1911.
The move is intended to provide commercial customers with greater convenience when it comes to fleet maintenance and acquisition, by making the Chevrolet BrightDrop vehicles available through select Chevrolet dealerships.
The Chevrolet BrightDrop, formerly known as the BrightDrop Zevo, is an electric delivery van that was unveiled at the 2021 Consumer Electronics Show. The van is available in two models, namely the larger BrightDrop 600 (originally the Zevo 600) and the smaller BrightDrop 400 (formerly the Zevo 400).
“With the addition of BrightDrop to the Chevrolet lineup, we are combining advanced EV technology with the dependability and widespread accessibility that only Chevrolet can offer,” said Scott Bell, Vice President of the Chevrolet division. “This move strengthens our EV offerings and reaffirms our role as a leading commercial brand that enables businesses large and small to get work done.”
BrightDrop EVs offer a GM-estimated 272 miles (438 km) of city and highway driving and incorporate a variety of driver-assistance features including pedestrian detection, automatic emergency braking and a rear-view camera. The vehicle has parking assistance and may be locked, unlocked or started remotely.
An unusual feature built into every BrightDrop van is that the steering wheel and seat are equipped with haptic technology, which will alert the driver of potential hazards through vibration.
While the Zevo name will disappear, the BrightDrop name will continue under Chevrolet’s stewardship. GM builds BrightDrop EVs at a plant in Ingersoll, Ontario that’s capable of turning out 50,000 vehicles per year.
Germany-headquartered Freudenberg Sealing Technologies has introduced cell caps and nonwoven cell stack envelopes for prismatic battery cells.
The battery cell envelopes use nonwoven materials that wrap the cell stack and, like conventional films, protect it during the assembly and provide electrical insulation. Nonwoven envelopes consist of a fiber network forming an ultra-homogeneous pore structure. The fibers are surface-treated for permanent electrolyte wettability to reduce the risk of entrapping gas bubbles as the cell is filled, and to help to keep the cell stack wetted over its lifetime.
Nonwoven materials filled with electrolyte also offer improved heat management within the cell compared to conventional foils, owing to the resulting higher thermal conductivity, according to the company.
The custom-designed cell caps, developed in collaboration with cell manufacturers, are tested to be gas-tight and to maintain this capacity throughout the battery’s cycle life. This optimizes performance in a range of operating conditions, minimizes the risk of gas leakage and increases safety. The cell caps also have strong mechanical resistance to peak loads and fatigue. They are compatible with various electrolytes, coolants and gases, enabling integration into different EV systems.
“In these customer projects, we combine state-of-the-art materials with intelligent design and merge our expertise in sealing technology and engineering plastics with our knowledge of stamping technology to ensure perfect sealing and a long cycle life for the cell caps,” says Giulia Richard, Global Marketing Director at Freudenberg Sealing Technologies.
US-based Terbine has launched its Mission Control system for EV infrastructure to provide monitoring and management of complex, multi-vendor charging networks.
Combined with the company’s cloud-based Charging Network Management Platform (CNMP), Mission Control is designed to make operating and maintaining charging systems more straightforward by giving network operators automatic detection, diagnosis and remedies for field problems.
Terbine Mission Control uses machine learning to predict when faults are likely to occur and issue alerts to system operators. It is linked with IBM’s Maximo asset and maintenance management platform to enable charging operators to issue trouble tickets, pre-order parts and dispatch service technicians.
Mission Control models the locations and types of individual chargers, along with onsite battery storage units, physical and cyber security monitors plus the service records of all network components. It can integrate feeds from vehicles, weather stations, fleet logistics systems and other elements of EV operations to create a comprehensive view of charging network health. Operators can zoom into a region and look at the real-time status of charging network elements.
“Getting EV charging up to enterprise standards requires a top-down, well-architected approach and sophisticated monitoring,” said David Knight, Terbine CEO. “Ensuring high uptime and dependability is critical to mainstream consumers and fleet operators adopting electric vehicles, as it was with cellular networks and many other technological evolutions.”
The global transition to electric vehicles (EVs) is accelerating, driven by a combination of environmental policies, technological advancements, economies of scale for Original Equipment Manufacturers (OEMs), compelling business cases, and shifting consumer preferences. As this momentum builds, the demand for robust EV infrastructure, particularly charging stations, is surging. This is particularly so when converting fleets from internal combustion engine (ICE) vehicles to EVs, presenting a range of technical, operational, financial, and environmental challenges. These challenges are interconnected, resulting from the complex web of interactions between vehicles, charging stations, and supporting energy infrastructure that requires careful analysis and management to ensure a successful and sustainable transition.
In this 1-hour webinar, including a panel discussion and live Q&A, we’ll explore how to overcome the complexities of fleet conversion and operations from multiple perspectives to achieve optimal financial, operational, and sustainability performance. The discussion will highlight a comprehensive approach to maximizing efficiency and sustainability in EV conversion and energy management, featuring Brightmerge’s innovative AI-enabled cloud-based platform that facilitates holistic analysis and optimization.
Highlights will include:
The EV conversion process including the deployment of charging infrastructure, integration of intelligent energy assets, and the implementation of advanced energy optimization strategies
Achieving system-wide efficiency: Strategies to optimize energy usage, reduce costs, and enhance reliability
Future-proofing transitions and fleet operations from energy dispatch and load management, to smart charging profiles, demand response integration and AI-driven optimization
An introduction to the Brightmerge platform: Learn how to manage and optimize EV fleets and supporting energy systems.
This webinar will be hosted by Charged on Wednesday, October 16th, at 11 am US EDT.
