The global transition to electric vehicles, both for individual and fleet use, has accelerated in recent years, and as the number of EVs on the road continues to rise, EV charging station providers often struggle to keep up. Providers face several challenges, including limitations of existing power infrastructure and high upfront costs of installation, as they race to meet growing demand.
This whitepaper examines these challenges and evaluates various EV charging power distribution solutions, with a focus on the advantages of ingress-protected track busways in providing flexibility and scalability.
A sign of the times? Dover Fueling Solutions, a well-known manufacturer of gas pumps and related products, has launched a new EV fast charger.
The Wayne PWR is designed and manufactured in Austin, Texas for the US market, and is NEVI-compliant. Wayne PWR’s cloud-based charge station management system allows owners to monitor the status of their chargers in real time, and the company’s nationwide Wayne approved partner service network provides remote diagnostics and proactive monitoring and maintenance.
The Wayne PWR is based on a cabinet/satellite architecture. Each cabinet can support up to four satellite units. Maximum charging power of the cabinet is 640 kW, and maximum power delivered by each connector is 400 kW. Each charging unit features a retractable cable, a 12-inch touchscreen and a POS payment terminal.
In some ways, the new charger sounds like a work in progress. It currently supports CCS1, but support for SAE J3400 (NACS) is “coming soon.” Also promised for the future: Plug & Charge support and liquid-cooled cables.
“One of the biggest challenges in the EV charging industry is reliability,” said Chad Bass, Director of Product Management for EV Charging at DFS. “Unlike competitors who white-label EV chargers through partners, we’ve developed and are manufacturing Wayne PWR right here in Austin. This direct control over production ensures that our charger meets the highest standards of reliability.”
US metal refining and recycling company Nth Cycle has begun operations in Fairfield, Ohio to produce premium nickel-cobalt mixed hydroxide precipitate (MHP), which is an essential component in a number of clean-energy, consumer and military applications.
The plant was installed at an existing 20,000-square-foot facility, and can process up to 3,400 tons of scrap materials to produce up to 992 tons of MHP per year. It will also serve as a test site for company partners. The company says the opening of the plant will reduce US reliance on China for MHP supply.
Nth Cycle says its modular Oyster system, by co-locating and operating on-site with recyclers, manufacturers and miners, can eliminate the need to build stand-alone refining facilities. Thus it will reduce not only costs but such factors as transportation, time-to-market, emissions and waste. The electro-extraction technology converts recyclable industrial waste and mined ore into a variety of critical metals using electricity rather carbon-fuelled pyrometallurgy.
“As the world becomes increasingly reliant on the critical metals that are the backbone of an electrified economy, it’s clear that the sourcing of those materials must be as clean and efficient as the future we imagine. A clean, unfettered and cost-efficient supply chain of nickel and cobalt, or MHP, accelerates our path to that future,” said Megan O’Connor, co-founder and CEO of Nth Cycle.
Fintech companies Nayax and Adyen have formed a long-term partnership to provide cashless payment technology to EV charging businesses.
Under the partnership, Netherlands-headquartered Adyen will join Nayax’s network of acquiring banks and integrate the company’s end-to-end payment and loyalty platform into Adyen’s single global platform. This will enable Israel-based Nayax, which provides payment processing devices and software for EV Charge Point Operators (CPOs), to expand into new regions such as Latin America and Asia-Pacific.
Nayax and Adyen will use a new global omnichannel payment service provider solution built for CPOs, which they will integrate using a mobile payment software development kit to support seamless card and online payments. The aim is to help resolve “significant operational issues for CPOs, which grapple with the complexities of reconciling payments between multiple providers,” according to the companies.
“Adyen is joining forces with Nayax to help further drive the platform’s offering in the fast-growing EV charging and automated self-service verticals,” said Roelant Prins, Chief Commercial Officer at Adyen.
The Norwegian Road Federation—Opplysningsrådet for Veitrafikken in Norwegian—has announced a seismic shift in electric adoption: There are now more EVs on the country’s roads than gasoline-powered autos.
There are currently 2.8 million passenger cars registered in the country and 26.3% are fully electric, just edging out the share of gassers. Diesels, however, remain the most common vehicle type, accounting for over one-third of Norwegian vehicle registrations. Currently, 34.8% are diesels, 7.3% are plug-in hybrids and 5.4% are hybrids.
“The electrification of the passenger car fleet is keeping a high pace, and Norway is moving rapidly towards becoming the first country in the world with a passenger car fleet dominated by electric cars,” OFV Director Oyvind Solberg Thorsen said. Thorsen predicts that the number of EVs will overtake diesel and gasoline vehicles by 2026.
Norway has been a global leader in EV adoption thanks to generous incentives from the government. These include exempting electric cars and trucks from sales and emissions taxes, reducing tolls and parking fees for these vehicles, and allowing EV drivers to use bus lanes.
Eighty percent of new vehicles sold in the Land of the Midnight Sun, as of 2023, are fully electric.
Modern electronic devices demand increasingly precise and clean power supplies. As supply voltages decrease and tolerances tighten, accurately measuring ripple and noise becomes crucial.
Engineers debugging face the challenge of detecting and quantifying these small AC signals riding on top of large DC voltages. Traditional measurement techniques often fall short due to limitations in oscilloscope performance and probe characteristics.
This application note addresses these challenges by providing practical guidance on optimizing measurement setups. By understanding the impact of factors such as oscilloscope noise, probe attenuation, input impedance, and probe loading, engineers can significantly improve the accuracy and reliability of their power supply measurements.
See the ideal configuration demonstrated with the new Keysight InfiniiVision HD3 Series oscilloscope and discover how high vertical resolution and ultra-low noise floor reveal the signals you’ve been missing.
ABM, a US-based provider of integrated facility services, infrastructure solutions and parking management, has signed an agreement with Samsung C&T Charging Solutions to become an authorized distributor and servicer of EVSIS-branded DC fast chargers.
Samsung C&T Charging Solutions is an equity partner of the South Korean manufacturer EVSIS, which is entering the US market. ABM will offer and service EVSIS chargers alongside its current charger portfolio. The chargers integrate with the cloud-based ABM EV OS platform, supporting scalable expansion, intelligent monitoring, remote operation management, reporting and automatic infrastructure diagnostics.
“This partnership reflects our growing relationship with Samsung, which spans our Technical Solutions and Manufacturing & Distribution segments,” said Mark Hawkinson, President of ABM’s Technical Solutions segment.
Telsonic’s advanced torsional SONIQTWIST® welding technology has been successfully applied in a groundbreaking solution for fixing silver-plated aluminum busbars using screws. This innovation, developed in collaboration with the KERN-LIEBERS Group, a producer of precision stamped parts, promises to set new standards for reliability and conductivity in electrical connections for industrial applications.
The Challenge: Securing Silver-Plated Aluminum Busbars
The KERN-LIEBERS Group has pioneered a technique to coat aluminum busbars inline with silver. This silver coating enhances the busbars’ conductivity but poses a challenge for secure attachment using screws, due to the relaxation properties of aluminum. The solution requires the integration of a copper sleeve into the busbar, providing a durable and electrically conductive connection that allows for screw fixation.
The Solution: Integrating Copper Sleeves with Ultrasonic Welding
To implement this solution, a copper sleeve is placed into a pre-punched hole in the busbar. The sleeve is designed with an oversized collar to facilitate the transmission of torsional ultrasonic vibrations through a sonotrode. This process welds the copper sleeve to the silver layer, ensuring the integrity of the silver coating is maintained.
Telsonic’s torsional SONIQTWIST® technology – the torsional welding system TSP3000.
Configuration Advantages
The integration of silver coating expands the compatibility of ultrasonic welding to new aluminum alloys. Ultrasonic welding offers a process-secure and long-term stable connection between dissimilar metals with minimal electrical resistance. The production of busbars with punched holes is cost-efficient, and integrating the silver coating into the production process eliminates additional transport costs for external coating.
This application was successfully executed using Telsonic’s torsional SONIQTWIST® technology. The torsional welding system TSP3000, depicted above, demonstrates Telsonic’s capability to meet the demanding requirements of industrial applications, ensuring reliable and conductive connections.
The US Department of Energy has selected US-based graphite processing technology developer Urbix to enter into award negotiation for $125 million of funding by the Office of Manufacturing and Energy Supply Chains to advance the construction of its commercial-scale graphite processing facility.
The funding, provided under the government’s Bipartisan Infrastructure Law, aims to expand domestic manufacturing of lithium-ion batteries for EVs and other applications. Urbix’s manufacturing facility in Muscle Shoals, Alabama will produce high-quality Coated Spherical Purified Graphite (CSPG) for US-based battery manufacturers. The facility will initially operate one commercial module capable of producing approximately 10,000 tons of CSPG per year, and may add more modules in the future.
The company’s long-term goal is to construct commercial projects strategically located throughout the US to strengthen CSPG supply chains and reduce reliance on foreign competitors for processed critical minerals.
“We are committed to using this grant to accelerate the development of our facility serving as a first step in providing a robust and secure end-to-end supply chain of premium graphite anode material that is vital to the industry’s ambitions,” said Nico Cuevas, founder and CEO of Urbix.
Switzerland-based semiconductor technology firm STMicroelectronics is introducing its fourth-generation STPOWER silicon carbide (SiC) MOSFET product range.
The company’s Generation 4 technology is designed to provide more power efficiency, power density and robustness than previous generations and is optimized for traction inverters in EV powertrains.
ST has completed qualification of the platform’s 750 V class and expects to qualify the 1200 V class in the first quarter of 2025. Commercial availability of devices with nominal voltage ratings of 750 V and 1200 V will follow as the company ramps up volumes through 2025, for applications operating from standard AC-line voltages up to high-voltage EV batteries and chargers.
The Generation 4 SiC MOSFETs feature a lower on-resistance (RDS(on)) than prior generations, minimizing conduction losses, and enhancing overall system efficiency. They offer faster switching speeds, which translate to lower switching losses—key for high-frequency applications and enabling more compact and efficient power converters.
The average die size of Generation 4 devices is 12-15% smaller than that of Generation 3, considering an RDS(on) at 25 °C, allowing for more compact power converter designs to save space and reduce system costs. The devices are designed to help bring SiC beyond premium EVs to mid-size and compact models.
The Generation 4 technology is robust in Dynamic Reverse Bias (DRB) conditions, exceeding the AQG324 automotive standard to ensure reliable operation in harsh conditions.
ST plans to introduce additional SiC products through 2027. The fifth generation of ST SiC power devices will feature high-power density technology based on planar structure. The company is also developing devices with improved on-resistance RDS(on) values at high temperatures and further RDS(on) reduction compared to existing SiC technologies.
“We continue to advance SiC MOSFET technology with innovations in the device, advanced packages, and power modules,” said Marco Cassis, President, Analog, Power & Discrete, MEMS and Sensors Group.
Japanese chemical company Asahi Kasei is introducing a new flame-resistant and highly flexible nonwoven fabric, LASTAN, for thermal runaway protection in top covers, busbar protection sleeves and other applications within an EV battery pack.
Mineral-based materials are typically used for thermal runaway protection, but they tend to be heavy and brittle, making them difficult to adapt to complex shapes in vehicles. LASTAN is a flame-retardant, non-mineral fabric made by air-baking a special acrylic fiber at 200-300° C. Its high flame resistance and electrical insulation are improved by a special coating process that also augments abrasion resistance. This allows the material to provide effective protection against particle bombardment from venting gas.
The temperature on the opposite side of LASTAN remains below 400° C even when a 1,300° C flame is applied, and no holes form in the fabric. The material has a limiting oxygen index (LOI) value of 50 or higher, which is above the value of 27 or higher generally considered to indicate flame retardance. In UL94 flame retardance testing, LASTAN obtained the highest rating of 5VA.
The material is resistant to high-pressure impact by particles of 200-500 µm. It also provides electrical insulating capacity of up to 3.5 kV at a thickness of 1 mm. LASTAN is highly flexible while maintaining its performance characteristics in sheets as thin as 0.8 mm, making it easy to process with ordinary tools.
“Having integrated production of LASTAN currently in Japan, Asahi Kasei is considering production in the United States and other countries in the future,” the company said.
US-based silicon battery materials manufacturer Group14 Technologies has received a $200-million grant from the US Department of Energy (DOE) through the Office of Manufacturing and Energy Supply Chains to build a silane plant in the US to diversify and strengthen the US battery supply chain. Silane is a key component in the materials for lithium-ion batteries, especially silicon-based anode materials.
The DOE has awarded over $3 billion in investments for 25 selected projects across 14 states from funds provided by the Bipartisan Infrastructure Law to support domestic production of advanced batteries and battery materials.
The proposed Group14 facility will produce silane requiring less capital and energy than conventional processes, according to the company. It will be able to directly feed silane to multiple silicon anode powder manufacturers via pipeline or container, reducing a supply bottleneck for the industry.
“While the largest source of silane today is China, Group14 and other silicon battery companies must strategically source this critical raw material domestically to support EV-scale battery production and reduce foreign battery supply chain dependence. Approximately 80% of the largest available source of silane produced in the US is controlled by a single company and earmarked for solar polysilicon. Additional domestic silane capacity is required to develop the silicon battery industry,” Group14 said.
Swiss energy storage provider Leclanché has developed a new Li-ion battery cell called XN50, which features Echion Technologies’ XNO, a niobium-based active anode material. “The cell provides integrators and OEMs with a differentiated battery option that outperforms existing chemistries in heavy-duty e-mobility, rail and marine applications,” says the company.
Leclanché is set to replace its current high-power lithium titanate (LTO) cell offering with XNO, and will offer a new set of battery module and pack solutions alongside its high-energy graphite/nickel manganese cobalt oxide (G/NMC) products.
Leclanché’s XN50 is commercially available now.
According to the company, the new cells deliver 50% higher energy density compared to LTO technologies, and maintain the highest safety and performance standards in extreme conditions. The XN50 cell can also deliver high power over an estimated cycle life of more than 10,000 cycles in heavy-duty applications. Studies have shown less than 3% capacity loss and less than 15% resistance growth after 1,000 2C/2C charge/discharge cycles at 45° C. Leclanché’s water-based cathode formulation ensures that the XN50 cell electrodes are free of PFAS.
“We are delighted to announce the launch of the world’s first commercial XNO Li-ion cell,” said Leclanché CEO Pierre Blanc. “XNO is soon set to displace the use of LTO within our product line, and it will complement our current G/NMC offering as the go-to fast charging battery solution for heavy-duty applications. We look forward to integrating XNO into our module and pack systems.”
“With XN50, Leclanché is setting a new standard for heavy-duty Li-ion batteries,” said Echion CEO Jean de La Verpilliere. “We have witnessed their exceptional drive, hard work and expertise first-hand over the last 3 years, and now look forward to seeing XN50 in the field at scale, which will enable end users to benefit from a battery specifically engineered for industrial and mass transportation applications.”
Japanese electronic parts manufacturer ROHM Semiconductor has launched a new range of medium-voltage N-channel MOSFETs featuring low ON-resistance for automotive applications, including motors for doors and seat positioning, as well as LED headlights.
ROHM has been supplying low ON-resistance MOSFETs for consumer and industrial equipment and has now extended its products to meet the requirements of the automotive sector. The components can be used in motors, including doors, seat positioning and power windows, as well as LED headlights, infotainment systems and displays and advanced driver assistance systems (ADAS).
Users can select from 10 models across three package types, depending on the application. Offered in voltage ratings of 40 V, 60 V, and 100 V, the new RF9x120BKFRA, RQ3xxx0BxFRA and RD3x0xxBKHRB incorporate a split-gate structure to achieve low ON-resistance. All the models are qualified under the AEC-Q101 automotive reliability standard, which contributes to greater miniaturization and high-efficiency operation.
The company offers compact DFN2020Y7LSAA (2.0 mm × 2.0 mm) and HSMT8AG (3.3 mm × 3.3 mm) packages for space-constrained sets like ADAS. The TO-252 (DPAK) package (6.6 mm × 10.0 mm) is available for automotive power applications. ROHM has further enhanced mounting reliability by using wettable flank technology for the DFN2020Y7LSAA package and gull-wing leads for the TO-252 package.
The company plans to expand its lineup in the future. Mass production of the DFN3333 (3.3mm × 3.3mm) and HPLF5060 (5.0 mm × 6.0 mm) packages is scheduled for October 2024, followed by 80 V products in 2025. P-channel products are also scheduled for future release.
Danish charging operator Clever is working with parking operator APCOA to convert parking spaces into EV charging hubs.
APCOA Denmark will advise site owners on integrating charging with parking, while Clever will handle the installation, maintenance, and day-to-day operation of their charging stations at the sites.
“Our ambition is to establish more than 5,000 public charging points at APCOA Denmark’s parking facilities by 2028, offering even more charging options where Danes need them most in their daily lives,” said Casper Kirketerp-Møller, CEO of Clever.
APCOA Denmark operates 120 charging points, which Clever’s subscription customers will be able to use as if they were Clever’s, starting later this year. And the APCOA FLOW app will soon support ad hoc payments for all of Clever’s 8,500 public charging stations to integrate parking and charging in a single app.
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.
