January 2015
TESLA TAKEOVER
UKIP Media & Events Ltd
January 2015
COACH JOURNEY
Why arent buses making the transition
from old diesel motors to clean new hybrids?
The Market
Leader in EVSE
Charge Station
and Battery
Testing
Key Standards
Include:
UN 38.3
CB Scheme
IEC 62133
IEC 61851
IEC 62196
SAE J1772
SAE J2953
SAE J2380
UN ECE R100.02
CHAdeMO
Please Contact:
icenter@intertek.com
www.intertek.com/
energy-storage
CONTENTS
In this issue...
vehicle technology
international
January 2015
JANUARY 2015
TESL A TAKEOV
ER
34
Ltd
WHATS NEW?
RAGING ELECTR
IC BULL
Boasting 910ps,
Lamborghinis
plug-in hybrid
first-ever
does not lack
brute power
January 2015
Wireless charging
supporters. Will is the EV future, say its
it ever become
a reality?
COACH JOURNE
COVER STORY
34. Tech takeover
Should the emergence
of tech companies as
big hitters in the EV
industry give traditional
car makers a headache?
06
18
28
14
25
32. EV speak
Actor, writer and E&H
columnist Robert
Llewellyn on two
game-changing
vehicles hes been
driving recently
www.infineon.com/automotive-eicedriver
EiceDRIVER SIL-Boost_215x275_EN_ANZ.indd 1
31.10.2014 16:36:15
CONTENTS
FEATURES
44. Hydrogen heyday
Toyotas fuel cell
sedan, the Mirai, goes
on sale in Japan in
early 2015, which
means production
FCEVs have finally
become a reality.
E&H finds out all the
engineering details
50. Public spectacle
As cities look for far
cleaner alternatives to
diesel-powered buses,
E&H visits various
local authorities that
are exploring the future
of public transport
58. No strings
How far away is the
world from widespread
wireless charging? And
could it really silence
electrification doubters
once and for all?
66. Power struggle
The EV industry is
waiting on the next
breakthrough in
battery technology, but
what could the future
look like as scientists
push ahead with
cutting-edge research
and development?
58
118
130
137
141
86
CONTENTS
174
PRODUCTS & SERVICES
145. IGBT gate drivers
(Infineon Technologies)
149. Reluctance-assisted motors (TM4)
152. Simulating BMS strategies (D2T)
154. Heavy-duty mild hybrids (AVL)
156. CAE driving models (Brel & Kjr)
158. BMS safety standards
(Lithium Balance)
160. Correct voltage conversions (Lear)
162. Electric powertrain testing
(D&V Electronics)
164. Ultracapacitor storage
(Maxwell Technologies)
166. Gold-plated resistors
(Power and Signal Group)
168. EV drivetrain control
(Actia Automotive)
170. Zero-emissions motoring
(Mouser Electronics)
172. Flywheel-based KERS (Flybrid)
173. Vehicle safety processors
(Toshiba)
174. Fuel cell power box
(Brusa Elektronik)
178
EDITORS NOTE
You know electric vehicles are starting to come of age when
companies synonymous with heart-thumping V6, V8, V10
and V12 creations start to embrace powertrain electrification.
Granted, what Toyota, Honda, VW, Renault, Nissan et al
are doing with sustainable transportation for the masses is
far more important on a wider society level, but we all know
developments like the McLaren P1, Porsche 918 Spyder and
Ferrari LaFerrari are what gets most of us car enthusiasts
going. And now even Lamborghini is at it, showcasing its
first-ever plug-in hybrid, the Asterion. The future of the
automotive industry looks not only green and clean, but very
exciting too the end is not nigh for supercars, sports cars,
hot hatches and performance sedans after all.
But the growing influence that powertrain electrification,
sustainable transportation and autonomous driving is
having in the automotive sphere is adding a new dimension.
Conventional car makers and suppliers, which have been
around for numerous decades, if not more than a century in
some cases, now not only have to do battle with themselves,
they are also facing attack from a new breed of tech
companies keen to fill the EV and self-driving vacuum.
Were a technology company making electric cars, said
Elon Musk to me a few months back at the RHD launch of
the Tesla Model S in the UK. And while Musks Tesla goes
from strength to strength, dominating the electric vehicle
arena with products that, generally speaking, are far more
desirable, go for longer, and offer much more power than
other EV rivals, Google, one of the worlds largest companies
across every sector and industry, is eyeing autonomous
driving. Heres an organization that generated revenues of
US$60bn in 2013 more than some established car makers
and ominously for the automotive industry, it clearly thinks
that self-driving electric cars are the future and, like the
internet, Google wants to own this space.
AVL Powertrain
World App
Part brain,
part
brawn
VITAL STATISTICS
Drivetrain: Four-wheel drive, front
wheels driven by electric motors
Displacement: 5,204cc
Power: 910ps
Torque: 560Nm
Bore & Stroke: 84.5mm x 92.8mm
Compression ratio: 12.7: 1
Top speed: 310km/h (192mph)
Acceleration
(0-100km/h): 3.0 seconds
Fuel consumption:
4.12l/100km (68.5mpg)
CO2 emission: 98g/km
Electric range: 50km
Power trip
3
1. Offering CO2 emissions of 98g/km and
a pure electric driving range of 50km, the
Asterion LPI 910-4 has been conceived
more for comfortable luxury daily cruising
than for ultimate track performance
2. The Asterions clear polycarbonate rear
engine cover features hexagon-shaped
cut-outs through which to view the 5.2 V10
3. Although it uses the engine from the
Huracan, the Asterion is based on the same
carbon fiber monocoque as the Aventador
4. Driven in pure electric mode, the Asterion
is the first front-wheel-drive Lamborghini
Up to 300 kW / 3400 Nm
2014-10-31 11:43:28
xxxxxxxx
Smart money
Said to cost a quarter of the price of a full hybrid powertrain
development, Hyundai-Kias diesel-electric propulsion innovation
makes sense on both a business and engineering level
that Grimm wouldnt disclose the names of, but another factor
that played a crucial role in this decision-making process is that
the technologys end-of-life recyclability is well established.
We can get material from lead-carbon batteries that we can
then sell on when were finished with them, whereas with
lithium-ion, you have to pay to obtain it and its not clear if
youll get anything back at the end-of-life stage.
In addition, lead-carbon helps with the general engineering
simplification theme entwined with this project in that the
battery, which is placed in the trunk of the Optima and i40,
requires no active cooling, is very durable and is so compact in
size that Grimm says it can easily be installed in just about any
Hyundai-Kia model and architecture. In fact, the entire package
is said to weigh no more than 50kg.
The 1.7-liter diesel engine is supplemented with a Valeodeveloped electric supercharger that works in addition to the IC
bases BorgWarner turbo, in the process eliminating turbo lag
and offering power and torque across the range, particularly at
low RPM. This latter point is especially pertinent to Grimm.
Five or six years ago, we were heavily investigating twostage turbocharging for diesels, and from our perspective we
didnt really see the value of this for our cars in Europe, he
explains, adding that the main reason for this was because
Kia didnt have a presence in the high-end performance diesel
sector. So, we went back and gave it some more thought, and
to bridge that gap between performance and economy, from
our point of view, electrification and therefore mild hybrids
is a much more appropriate technology.
He continues, When you have a two-stage turbocharger,
you do get low-end torque and high-performance, but theres
only a small step to be had when it comes to CO2 benefits. With
this mild hybrid, we have the possibility to use recuperated
energy, making it very efficient.
The 48V e-machine delivers some 10kW of electrical
power, which in the i10 results in total system output of 155ps
and 360Nm torque. It is safe to assume that a similar 1520% increase in overall power in the Optima is also realized,
although Kia is not confirming any actual numbers yet.
We use this power for starting the engine, adds Grimm,
because it enables us to ramp up the engine to 800rpm, at
which point the combustion starts, which means its a very fast
and very smooth operation.
Although Grimm cites such a smooth engine startup process
as a big benefit, another important plus-point is what the
2
2. The mild diesel-hybrid
development has been
designed so that it can be
easily installed in most
current Hyundai-Kia
architectures, including the
third-generation Sorento
ition
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NETZSCH Instruments
North America, LLC
129 Middlesex Turnpike
Burlington, MA 01803-3305
USA
Tel.: (+1) 781 272 5353
Fax: (+1) 781 272 5225
nib-sales@netzsch.com
www.netzsch.com/n29169
Anzeige-NIB-IBC284-215x275.indd 1
06.11.13 14:32
City
slicker
Urban warrior
On a
charge
VITAL STATISTICS
Boost action
Displacement: 1,969cc
Bore x stroke (mm): 82 x 93.2
Compression ratio: 10.8:1
Electric motor:
Driving rear wheels; 60kW
Transmissions: 8-speed Aisin
Engine block and cylinder
head: Aluminum
The eighth-generation
Passat is the latest
MQB e-powertrain
development from VW
Sibling sharing
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EV NEWS
GKN PRODUCES WORLDS FIRST 2-SPEED ELECTRIC AXLE
GKN has developed the automotive
industrys first 2-speed eAxle for hybrids
and EVs, with the technology being
applied for the first time in the BMW i8.
The eAxle enables automakers to
produce axel-split hybrids. A conventional
or hybridized engine provides the primary
power to either the front or rear wheels,
with the other axle being driven by an
eAxle module. The technology responds
intelligently to deliver an instant, hightorque, all-wheel drive experience, a
useful pure electric range or a refined,
efficient parallel-hybrid mode.
Giving the electric motor an additional
gear ratio improves acceleration and
the pure electric range, benefiting both
driving dynamics and CO2 emissions.
GKNs 2-speed eAxle also enables the
motor and all its associated systems to
be downsized, reducing mass and further
increasing efficiency.
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New
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Discharge power recycled to AC line for cooler, more energy efficient operation
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Test cell
Prior to achieving final sign-off, Venturis newest EV
creation underwent extreme testing and validation
engineers to opt
for a T-shaped pack,
also created in-house
by the car makers
technical department,
which is housed inside a
carbon composite Kevlar chassis.
An aluminum honeycomb structure
provides optimal protection for both
the battery pack and passengers.
For these tests we used real cells because
otherwise we would have lost time re-testing,
adds Baldet. We also ran basic functional safety
tests where we over-charged and over-discharged
the battery to check that the fuse and the
conductors were working properly.
We conducted shock tests to ensure that the
pack does not displace in the event of sudden
acceleration or deceleration, and to ensure it does
not short-circuit either. That involved running a
chassis, with the battery inside, into a wall. We
also did immersion tests where the battery was
soaked in 1m of water for 30 minutes.
According to Baldet, a particular focus
throughout the development program of the
America was placed on ensuring minimal contact
resistance between the cells: When current gets
TECH SPEC
Engine type: Permanent
magnet synchronous
Battery system: Lithium-ion polymer;
53kWh capacity
Power output: 300kW; 480Nm torque
Top speed: 220km/h
Acceleration
(0-100km/h): 4.5 seconds
(0-200km/h): 14 seconds
TIGHT SQUEEZE
DC Bus
Measurements
3 Phase Inverter Output
Measurements
PERSONALITY PROFILE
PERSONALITY PROFILE
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Toshiba_auto_183x115.indd 1
19/05/2014 10:31
MERCEDES E 300
BLUETEC HYBRID
Across the years weve never hidden
the fact that at E&H we are big fans of
diesel-hybrid powertrains. Yes, they
are expensive to develop and yes, this
is a typically European standpoint, but
on many engineering levels they just
make sense. And slowly the market is
becoming increasingly populated with such
drivetrains, following PSA Peugeot Citrons
lead a few years ago. The latest name to
enter the diesel-hybrid arena is MercedesBenz, in the form of the E 300 Bluetec
Hybrid, which essentially puts Daimlers
much trusted and rather underrated 2.2-liter
four-cylinder CDI together with an electric
motor thats placed between the IC base
and the 7G tronic transmission. The 2,143cc
OM651 diesel creates 205ps and 500Nm of
torque between 1,600 and 1,800rpm, while
the electric portion of the E 300s setup
sees a compact 35-cell, 0.8kWh lithiumion battery pack from Deutsche Automotive
supply power to a 20kW donut e-motor
thats good for 280Nm. Impressively, the
part electrification of the E 300 Hybrid has
resulted in just a 99kg weight increase
over the standard E 250 CDI. On the road,
theres no denying that the E 300 Hybrid
is very capable. In this segment, power
and performance needs to be blended with
a refined upmarket drive, and while the E
Class from the outset has been designed to
deliver those goods, the hybrid part of the
E 300 is not just there for show or to pay lip
service to the green lobby. We very nearly
matched Mercedes claimed combined fuel
economy figure of 4.1 l/100km (68.9mpg),
and with emissions being 109g/km, such
readings are not bad at all for a sedan that
sprints to 100km/h in 7.5 seconds.
TESLA MODEL S
E&H was one of the first to test a right-hand
drive Tesla Model S and, simply put, its unlike
anything else on the road today, be that cars
powered by humble diesel or gasoline engines
or even the new-generation of EVs. Its the
numbers that first set the Model S apart from
the chasing pack. Depending on the spec,
theres 400+ ps and 600Nm of torque to be
had, all of which puts the Tesla sedan firmly in
Porsche, BMW M, Mercedes-AMG and even
Maserati territory. Green no longer equates
with boring. And that torque is instantly
available, so tap the accelerator pedal with
care; a 0-100km/h dash at the lights takes a
mere 5.6 seconds remarkable for a car with
large proportions weighing the best part of
VOLKSWAGEN E-GOLF
Our Tesla write-up (above) is rather gushing
and name drops the BMW i3 and i8 along
with the sublime Model S as being the
finest examples of EV engineering to date.
But can the Volkswagen e-Golf join such
illustrious company? The short answer is
Yes! And while were at it, the e-Up (see
last issues Electric Powertrains On Test) can
also be thrown into that mix. Having always
planned for an all-electric derivative when
the seventh generation Golf was first being
formed many years ago within VWs R&D
labs in Wolfsburg, Europes largest car maker
has without too much engineering fuss
swapped its wonderful array of gasoline
and diesel engines for an equally striking
e-powertrain for the all-electric Golf. That
out with the IC, in with the electric
replacement has been a seamless
transition thanks mostly to VWs
highly impressive and very flexible
and not to mention modular
MQB underpinnings. This all means
that e-Golf benefits from a 115ps
synchronous motor, code-named
EEM 85, that delivers 270Nm
torque. The motor and the e-Golfs
EQ 270 single-speed gearbox with
integrated differential have both
been fully developed in-house
FREE SERVICE!
electric &
hybrid vehicl
e techno
logy intern
ationa
l
January 2015
RAGING ELEC
TRIC BUL
KEOVER
How Elon
Musk and
revolutionizin
other tech
giants are
g the elec
tric vehicle
movement
L
Boasting
910p
plug-in hybri s, Lamborghinis
first-ever
d does not
lack brute
power
WHAT LIES
BENEATH
Wireless charg
ing is the
supporter
s. Will it ever EV future, say its
become a
reality?
COACH JOU
RNE Y
Why aren
t buses maki
old diesel
ng the trans
motors to
ition from
clean new
hybrids?
LEARN MORE
ABOUT OUR
ADVERTISERS
NOW!
Visit:
www.ukipme.com/info/ev
to request exclusive and
rapid information about
the latest technologies
and services featured
in this issue
www.ukipme.com/info/ev
TESL A TA
UKIP Media
Llewellyn
OPINION
The Mitsubis
hi Outlande
charging ab
r PHEV, with
ility, is a
its rapidgenuine SU
V ga me chan
ger
Hybrid and electric powertrains use less fuel and emit lower
emissions. But drivers want more mileage and better performance. BorgWarner knows how to improve efficiency, reduce
weight and boost performance for the fun-to-drive experience
drivers crave. As a leading automotive supplier of powertrain
solutions, we support your engine and drivetrain designers to
meet specific challenges and optimize systems. For powertrain
innovations that deliver results, partner with BorgWarner.
borgwarner.com
TAKEOVER
S
1. Caption style
2
RISE
RISEOF
OFTHE
THETECH
TECHGIANTS
GIANTS
experience of what it actually means to be an established
car manufacturer in the automotive industry.
And Kim Wagner, senior partner at BCG and co-author
of its 50 Most Innovative Companies report, agrees: The
greatest challenge for the tech companies is typically that
they start off as gifted amateurs. While they bring with
them a fresh perspective and a deep understanding of
their core technologies, they have to learn by doing, so
they often spend time learning the things that industry
insiders take for granted.
Nevertheless Wagner says the new names still hold an
advantage simply because of the way they operate. The
learning culture of technology companies is well-suited to
pushing the boundaries of current technologies, and their
successes will naturally encourage the traditional players
in the space to push forward as well.
So, starting with a blank sheet is undoubtedly liberating
when developing new technologies and progressing them
to a proof of concept stage. But it is here where reality will
kick in. Ultimately, in order to move forward on any scale,
the tech pioneers will need supply chains, manufacturing
capacities and a robust commercial model to actually
launch a product successfully. One only needs to look at
Teslas journey to where it finds itself today, and then look
at the so-called many new names that have been far less
successful, like Fisker, Venturi and Think.
TIME WITH
ELON MUSK
As the pioneering
all-electric Tesla
Model S is launched
in the UK, E&H was granted an exclusive audience with
one of the worlds leading tech visionaries Space X,
Solar City, PayPal and Tesla founder Elon Musk
Off-the-shelf experience
Were a technology
company making electric
cars. Whats very important
is sustainable transport.
Autonomous driving is nice
to have but not required;
sustainable transport is
whats required
Elon Musk, founder, Tesla
2
2. Teslas gigafactory, a
lithium-ion battery base,
is to be built at the Tahoe
Reno Industrial Center in
Storey County, Nevada.
Set to be operational by
2017, the projected cost to
build the facility is about
US$5bn. Tesla expects to
achieve a minimum of 30%
reduction in production
cost for its car batteries
when the factory opens
3. The Tesla Model X
full-size crossover utility
vehicle will weigh about
10% more than the Model
S and will share about
60% of its parts content.
Tesla expects to begin
deliveries in Q3 2015
EL A hnolog y
ec
powe rM
D r i ve T
ELA -C
powerM
t Sy s t e
n
A
e
L
m
E
e
M
g
powe rat ter y M a n a
B
powerMELA-mBMS
Traction or
GenSet Systems
Synchronous water cooled motor or generator
specially developed for EV&HEV applications
up to 100kW.
Electronic controller which support the
requirement of the motor or generator.
Both units can be used as a kit or as separate
system.
Sensor-Technik UK Ltd.
Unit 21M Bedford Heights Business Centre
Manton Lane Bedford MK41 7PH UK
Tel. +44 (0) 1234-270770
www.
sensor-technik.com
Anz_powerMELA_Electric-Hybrid-Vehicle_Technology-Magazine_01-2015_powerMELA-C_MBMS_90x250.indd
30.10.2014 13:35:031
POWER TRIP
Whether its decision to launch the
new Model S P85D a week after
the Paris Motor Show was a deliberate
move to signal its independence from
(and indifference to) the rest of the
automotive world, Tesla was always
going to grab the industrys attention
with its latest creation.
The Model S P85D is, without doubt,
Teslas most important launch to date.
Its dual motors, one on each axle,
digitally and independently control
torque to the front and rear wheels,
resulting in precision control of traction.
Furthermore, digital torque controls
and a low center of gravity provide
very competent handling, or so the
companys founder, Elon Musk, says.
But it is the power and performance
that really sets the Model S P85D
apart from all other EVs. Its capable of
0-100km/h (0-60mph) supercar-like
sprint times of 3.2 seconds, delivering
100% of its huge peak torque from
a standing start. This, ladies and
gentlemen, is enough to outperform
any
gasolinepowered car in the
same class, whether
that might be a Maserati,
BMW M, Mercedes-AMG and so on.
The launch of the Dual Motor Model
S also showcases Teslas strategy for
smarter vehicles, with the inclusion
of Autopilot, hardware that includes
forward radar, 12 long-range ultrasonic
sensors, numerous cameras, and a
digitally controlled electric braking
system. It also promises to activate
the potential of this system with future
software updates, so as it develops
active safety, collision avoidance
and a multitude of other functions,
Autopilot, says Tesla, will be able to
relieve drivers of the most boring and
potentially dangerous aspects of road
travel, while allowing the driver to
remain in control of the vehicle.
Where to next?
1
1. The self-driving Audi
RS7 took just over two
minutes to complete a lap
of the Grand Prix track in
Hockenheim, Germany
www.lear.com
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BN 1405 11
07-08-2014 09:54:12
WIRELESS CHARGING
WIRELESS CHARGING
Taking
charge
Il l u
st r
at i
on
:M
ag
icT
or
ch
WIRELESS CHARGING
You might not see it on everyday passenger cars just yet, but
the technology to enable wireless vehicle charging is not
only available, its already been proved. The technology
itself is not a stumbling block any longer, states Andrew
Daga, chairman and CEO of Momentum Dynamics. If
you were to walk in here today, we would turn on the
switch and show you that it works. There is no impediment
to the technology. Momentums wireless development,
which is currently operating in a number of pilot programs,
can charge at power levels up to 50kW assuming the
vehicle in question has a battery that can take it with
efficiency levels in excess of 90%, and has been designed
to safely and reliably transmit power through both air
and water.
Main: Qualcomms Halo development
is currently being used in Formula E
to charge the BMW i8 safety car
Right: Qualcomm has deployed its
technology in numerous projects
around the world. Shown here is
dynamic charging in action
WIRELESS CHARGING
Momentum Dynamics
Wireless Power
Lets Go.
www.momentumdynamics.com
In principle, its very simple: we have developed a new product platform as a catalogue of electric
drive modules for automotive use. They are perfect for commercial/public transport vehicles and
allow you to put together your individual drive solutions quickly and with ease.
Find out more at www.Lenze-Schmidhauser.com
lenze_advert_schmidhauser_MOBILE_E&H Magazine_183x115_en_1_2015.indd 1
05.11.14 09:50
WIRELESS CHARGING
KNOWLEDGE OF POWER
While the basic concept of wireless
charging is relatively simple to grasp the
transfer of energy between objects via an
electromagnetic field this hasnt stopped
a few misplaced beliefs in the technology
from springing up.
Theres a preconception that wireless
charging is more expensive and less
efficient than plug-in, says Momentums
Daga. Actually, the reverse is true. A
WIRELESS CHARGING
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Thermal Materials
Thermal Substrates
P wer
rangers
If electric vehicles are to provide more power, go longer
on a single charge and eventually replace IC-engined
products, battery technology needs to reach a new level.
But can that be achieved with lithium-ion chemistry?
WORDS: MAX MUELLER
Advancing modeling
technology enables
battery simulation
on electrode, cell
and pack level
MODEL BEHAVIOR
The role that simulation plays in battery
design and development is as important as
it is complex. In terms of modeling, batteries
pose multiscale problems, with phenomena
occurring on different levels ranging from
the microscopic to millimeter, centimeter
and decimeter scales. Despite this, data
must be correlated to make sense of the
overall picture. The chemical reactions
that happen within a cell will affect battery
performance and, in turn, the cooling strategy
will influence the electrochemistry, explains
Sandeep Sovani, director of global automotive
industry at Ansys.
Another challenge is the complexity of
interconnected physics, such as electrical,
fluid and thermal fields. Four or five years ago
battery simulation was restricted to regular
finite element analysis to calculate things
like flow behavior for the cooling strategy.
But a recent partnership project with GM, the
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2014 EnerSys. All rights reserved. All trademarks and logos are the property
of or licensed to EnerSys and its affiliates unless otherwise noted.
www.enersys-emea.com
Quest
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The result of 10 years of study and research,
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research seeks to establish the scientific
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make efficient use of energy and natural
resources in an environmentally sound
manner. This spans engineering applications
and the supportive fundamental science.
The overarching theme of his work is
electrochemistry in non-aqueous media.
Research interests include liquid metal
batteries, metals production by molten oxide
electrolysis, rechargeable solid polymer
batteries and aluminum-ion batteries.
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OEM
OEM INTERVIEW:
INTERVIEW JAGUAR LAND ROVER
All shook up
A recent trip to Jaguar Land Rover confirmed that project
Ingenium is just the start of a leaner, more efficient engine
future for the British car maker, which will soon also
include a variety of all-new e-powertrain creations
OEM INTERVIEW:
INTERVIEW JAGUAR LAND ROVER
Emissions mission
138kg
21%
23%
72,000
hours of dyno testing and 2 million of
real-world miles testing was undertaken
during Ingenium development
29,000+
JLR employees globally
3.5bn
(US$5.6bn) investment will result in
50 new models in five years
SELF-DRIVING INGENIUM?
JLRs investment in Ingenium ensures that its new vehicles will
come equipped with efficient engines brimming with technology
that also provide power and performance. And on a companywide level, the new powertrain family also guarantees the car
makers future, bringing in-house all engine R&D expertise and
production capability, allowing it to react to changing market
demands, and implementing new technology. But what does
the long-term future look like for JLRs powertrain plans? And
might Ingenium one day even include self-driving aptitude?
Autonomous driving, from our point of view, is a
continuous journey that started in 1996, when
Jaguar was the first to bring ACC in the XK to the
market, says Wolfgang Epple, JLRs director
of research and technology.
Over time, various supporting
functions have been implemented,
such as emergency braking and subfunctions that help to make the car more
autonomous, taking more of the load
away from the driver. That is a continuous
journey, and from our perspective, it will
take another 5-10 years before we as an
industry can offer driving autonomy.
However, the former BMW, Lotus and
Proton chief engineer says that when discussing
autonomous driving, its important to think about the
enjoyment people get from behind the wheel. Basically, every
driver has two states. The first is commuting from A to B, a
tedious work /school journey that really nobody likes to do.
The other is the more emotive state, driving on country roads
and enjoying the fun of motion and mobility. For us, the tedious
one is where autonomous comes in, because there the driver
can do something else in the car, being more productive and
staying connected. The other, second state, is where we want
to maintain the joy of driving and being in control.
ELECTRIC MOTORCYCLES
ELECTRIC MOTORCYCLES
Easy rider
Analysts have predicted that 2015 is to be a breakout year for electric motorcycles,
as more products come to market and consumers switch on to battery-powered
biking. So E&H hit the road to get the insider view from the manufacturers, while
also investigating the wider implications for electromobility on two wheels
WORDS: FARAH ALKHALISI
ELECTRIC MOTORCYCLES
LIVE WIRE
Until now, making all electric
motorcycles has been the preserve
of small start-ups and custom
bike-builders but the established
brand-names in the two-wheeled
world dont come any bigger or more
legendary than Harley-Davidson,
whose electric bike, the Project
LiveWire concept, has been out
on tour across the USA to gauge
consumer reaction.
LiveWire is all part of the
111-year-old companys ongoing
plans to widen and future-proof
its range and its global reach,
following a general overhaul
of its product development and
manufacturing operations. Project
LiveWire is just one element in our
efforts to preserve and renew the
freedom to ride for generations
to come, explains Matt Levatich,
president and COO, at LiveWires
unveiling earlier this year.
ELECTRIC MOTORCYCLES
Harley-Davidson is giving
away little technical detail on
the bike as yet, but the basic
specifications of the prototype
include a 0-100km/h (0-60mph)
time of around four seconds, a
top speed of 148km/h (92mph),
a 96km (60-mile) driving range
and a 3.5-hour recharging time
on a Level 2 (240V ) charger. The
LiveWires lithium-ion batteries
are sourced from an as-yet
unnamed technical partner, and
its electric motor thought to
develop around 75ps and 70Nm
of torque has been developed
with input from San Franciscos
Mission Motors. This latter
nugget of supplier information is
particularly noteworthy because
Mission is bringing its own
electric superbikes to market
via its now-independent Mission
Motorcycles division. In addition,
the company is also evolving as a
product supplier and engineering/
DC/AC Converters
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ELECTRIC MOTORCYCLES
ELECTRIC MOTORCYCLES
ON PATROL
Electric motorcycles are increasingly being
deployed by police and security forces
for their stealthiness as well as energy
efficiency and zero-emissions operation.
Oregon-based Brammo has moved into this
niche, and Californias Zero Motorcycles
has so far supplied 100 bikes to the
Colombian city of Bogota last year, 60 to
the Hong Kong police, plus further bikes
to various municipalities in the USA. We
have an expectation that fleet is going to
be a significant proportion of our business,
confirms CTO Askenazi.
Zero has also built prototypes for military
trials. One of the requirements for the US
Special Forces was 60-second charging,
and there is no technology right now that
will allow true 60-second charging to
A key growth
area for Zero
Motorcycles has
been the supply
of e-motorbikes
to police forces
around the world
maxwell.com
ENFIELD
8000
created
Against an energy crisis backdrop, one company
s. So just
an all-electric urban runaround in the early 1970
lution?
why didnt the Enfield 8000 kick off the EV revo
WORDS: JOHN SIMISTER
a 1966
The Enfield 8000 grew out of a winning design in
a
Electr icity Council competition for a contract to build
the
on
based
name,
its
e
despit
d,
small electr ic car. Enfiel
the
Isle of Wight, had started its electr ic-car program with
it
before
made
were
these
of
three
465 in 1969, but just
lwas re-imagined as the fractionally more conventiona
year.
that
later
ed
looking 8000, reveal
It was in 1973 when Enfields moment of oppor tunity
first
really came. The Yom Kippur War had triggered the
r
energy crisis as oil supplies suddenly lost their forme
nly
sudde
power
ic
electr
and
nty,
taken-for-granted certai
if it
seemed to represent an energy-secure future even
still depended rather too much on coal-fired power
stations. Then Britain suffered its miners strikes, which
put paid to that. Never theless, between them, the
s up
Electr icity Council and various local electr icity board
ENFIELD
8000
didnt
seconds from rest, but prov ided you
often,
too
s
eme
extr
visit these performance
full
one
from
s)
mile
(50
m
80k
get
t
you migh
battery charge.
at
That figure might have been somewh
tive
nera
rege
of
form
e
som
better had there been
the
off
foot
your
Lift
y.
bilit
capa
ing
brak
the same
accelerator and the car continues at
the
in
y
arth
McC
e
Mik
rved
obse
d,
spee
ly
week
of
on
editi
September 8, 1973,
of the
magazine Motor. It is an indication
any other
and
e
tanc
resis
extent to which rolling
inated.
elim
been
have
ions
frict
sary
unneces
arthy
McC
to
out
ted
poin
Eng ineer Adraktas
s, and
part
ing
mov
t
eigh
only
were
e
ther
that
perhaps
four of them were wheels. That was
0s
800
the
of
tion
lifica
simp
glib
ly
an over
its
ze
hasi
emp
does
it
system workings, but
used
enth
y
arth
McC
.
tion
plica
com
of
lack
The non-proprietary
ing
elds, typically using components of the 8000
about the smooth ride, the quiet runn
and dow n the country bought 65 Enfi
s, the
click
s
unit
er
rol
furth
a
cont
or
with
and
,
e
mot
ders
Greec
the
in
r-rea
from
made
t
were
apar
them to transpor t traveling mete
ing
turn
tiny
the
Isle
n
es,
the
to
uctio
brak
ted
expor
until prod
light and prog ressive
55 examples going to private owners
Any
ing:
of Wight for assem bly
hold
road
llent
exce
the
and
e,
circl
ended in May 1976.
twitch
ponents and
corner is taken flat-out, with just a
From 1973, the non-proprietary com
eld had
Enfi
the
And
and
el.
ce
whe
Gree
ing
in
e
steer
mad
of the
subsystems of the 8000 were
arch
Rese
stry
Indu
an
,
or
assembly
even passed the Mot
then exported to the Isle of Wight for
crash
-on
head
)
m/h
(48k
eld
ph
Enfi
30m
the
use
ons
ciati
beca
Asso
arrangement that came about
its
than
car
safer
ire
a
iona
ping mill
test; this was probably
company was owned by Greek ship
engineered by
most recent emulator, the G-Wiz.
Giannis Goulandris. The car itself was
e
worked
also
had
who
,
ktas
In 1969, Enfield took a pair of prototyp
Adra
tine
stan
Con
fellow Greek
posium
sym
d
worl
be
the
for
re-tu
ia
squa
forn
a
Cali
used
to
0s
and
800
on the Apollo space project,
t.
panels. The
of electric vehicles, the first such even
spaceframe structure clad in aluminum
h
muc
ered
trigg
USA
tic
the
plas
ss
lded
acro
e
-mo
driv
The
shor t-lived 465 had an injection
but
ers,
own
on
stati
opprobrium from gasmonocoque structure, incidentally.
Reagan
ng, rear-wheelthen-Governor of California Ronald
Proprietary parts included a coil-spru
(Los
idea
llent
els
whe
exce
an
d Bug; 10in
thought the Enfield
drive back axle designed for the Bon
and
lem)
le
prob
g
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smo
r
swin
t,
majo
pivo
a
lowhad
ed,
eles
Ang
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a new
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suggested building the little cars in
front suspension (and rear lights) from
, of
ened
i,
happ
r
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neve
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It
orig
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an
facto
ia
than
forn
ter
Cali
The Enfield was 200mm shor
applied
sure
pres
and
of
s
use
seat
just two
course, possibly beca
its tiny size made possible by having
who
es
pani
red
com
cove
oil
net
the
bon
by
t
ris
shor
land
the
e
Gou
to
a stowage ledge behind, whil
ries, each of them
used his ships.
four of the eight motive-power batte
sat under the
The problems of restr icted range and
with a 110A h capacity. The other four
eld
s,
light
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TRANSMISSIONS
TRANSMISSIONS
Multishift
Here, attendees will learn about technology applications of the manufacturers hybrid
and electric vehicles, powertrain technologies and components, and about supporting
technologies such as advanced energy storage and charging systems.
www.sae.org/hybridev
P141639
www.midtronics.com
TRANSMISSIONS
Dual agenda
CVT comeback
Cost is less of an
obstacle than you might
think, because multispeed
solutions can use a
lower-cost motor for
the same installed
performance as a singlespeed transmission
Paolo Mantelli, head of performance automotive
engineering, Oerlikon Drive Systems
Number crunching
Top: Paolo Mantelli, head
of performance automotive
engineering at Oerlikon Drive
Systems, believes that there is
an industry-wide shift toward
automated transmissions
Right: Oerlikons eDCT system
provides EVs with greater
range, while reducing vehicle
weight and battery pack size
sae.org/congress
P141635
YOUR
SOURCE
FORFOR
COMPREHENSIVE
HARNESS
YOUR
SOURCE
COMPREHENSIVE
HARNESSASSEMBLIES
ASSEMBLIES
YOUR
SOURCE
FOR
COMPREHENSIVE
HARNESS
ASSEMBLIES
From initial designin and prototyping to preserial
From initial designin and prototyping to preserial
phases
Power
Signal
Group
provides
the practical
From initial
designin
and
prototyping
to
preserial
phases
&
Power
& Signal
Group
provides
the practical
assistance
to implement
electrification
strategies:
phases assistance
Power
& to
Signal
Groupelectrification
provides
thestrategies:
practical
implement
assistance to implement electrification strategies:
Delphi distribution
partner partner
for overfor30over
years
Delphi distribution
30 years
Delphi distribution
fortransportation
over
years
Focused
on automotive
and
Focused
onpartner
automotive
and 30
transportation
Delivering
HEV harnesses
in smaller
quantities
Focused
onHEV
automotive
andintransportation
Delivering
harnesses
smaller
quantities
Providing
"off thesolutions
shelf"
solutions
Delivering
HEV
harnesses
in smaller
quantities
Providing
"off
the
shelf"
C ALL ON POWER & SIGNAL GROUP FOR YOUR DELPHI HIGH VOLTAGE NEEDS!
C ALL ON POWER & SIGNAL GROUP FOR YOUR DELPHI HIGH VOLTAGE NEEDS!
www.powerandsignal.eu
www.powerandsignal.eu
www.powerandsignal.eu
TRANSMISSIONS
TECHNOLOGY TRANSFER
The move away from the traditional
engine-gearbox layout, combined with
increasing electrification in a diversity
of market segments, has opened up
opportunities for small start-ups as
well as the major suppliers and far
greater potential for technology transfer
between different industries and
sectors. One example of this comes from
London-based electric motorcycle maker
Agility Motors, which has won an award
from the UK governments Technology
Strategy Board for its multispeed
transmission for electric vehicles,
developed initially for a motorbike.
It literally has no clutch, says Agility
CEO Lawrence Marazzi. This means far
fewer components, much lower weight
and lower cost, and you can increase
the efficiency and change the way the
transmission interacts with the rider if
you control various elements.
Agilitys debut product, the Saietta
R sports bike, is single-speeder, but
the multispeed transmission has been
designed to be licensed for a wide
variety of uses.
When we developed it, we knew there
would be a great deal of interest in it for
light commercial vehicles. The system
can be scaled and changed for all sorts
of other applications, but is absolutely
applicable right now in its current design
for light commercial vehicles, says
Marazzi, describing the technologys
low cost, efficiency and tiny size, and
suggesting that it would also be suitable
for marine and industrial applications.
TRANSMISSIONS
Integrated innovations
POWER CONVERSION
FOR THE ROAD AHEAD
NO MATTER HOW TOUGH
THE ROAD GETS.
For years, DRS has been designing rugged power solutions for military
applications. We leverage that expertise for every vehicle power product
we build. Our inverters and chargers offer clean, reliable power conversion
and inversion for E-REV, commercial and military applications. Whether
the need is for power conversion between multiple sources and loads or
increasing power capacity to meet vehicle demand, we provide cost-effective,
dependable on-board exportable power solutions.
COMMERCIAL VEHICLES
Degrees of
separation
Theres no denying that all-electric commercial
vans are having an impact in specific urban-based
projects, but do hybridized powertrains promise
more versatile and cost-effective solutions?
COMMERCIAL VEHICLES
COMMERCIAL VEHICLES
Heavy-duty hybrids
COMMERCIAL VEHICLES
But its not just the OEMs that have been busy
developing e-powertrains for van and truck
applications alike. Modular systems such as
the ZF TraXon Hybrid development offer
further possibilities. The German Tier 1s
module, mounted in the clutch bell housing,
integrates a 120kW e-motor and enables
low-speed all-electric driving, stop/start,
energy recuperation and boosting of the IC
engine, as well as the direction of otherwise
wasted energy for auxiliary power supply to
items such as cooler units or to facilitate
additional functions such as coasting (engine
switch-off at speed) and quiet, efficient
electric power take-offs, all to give a projected
fuel saving of around 5%. Bosch, meanwhile,
suggests fuel savings of up to 15% from its
parallel hybrid system, as tested in a 40
metric ton truck, which enables all-electric
start-up, a short electric-only range, stop/start
and electric powering of peripheral systems.
Boschs compact module slots between an
existing engine and gearbox, and can work in
combination with waste heat recovery for
energy saving at different points in its
operating cycle.
Paul Rivera, managing director for hybrid
and electronic systems at Ricardo, says that
2. The Metropolis is a
range-extended waste
collection vehicle that
offers local authorities
a low emissions solution
Introducing
www.vanner com
@VannerHybrid
COMMERCIAL VEHICLES
SPECIAL DELIVERY
COMMERCIAL VEHICLES
Allegro A1160 ad Electric & Hybrid Vehicle Technology Jan 15:layout 1 30/10/2014 14:25 Page 1
Features:
www.allegromicro.com/camp1223
Representatives
ALLREM
94616 Rungis Cedex, FRANCE
Tel: +33 (0) 1 56 70 03 80
E-mail: info@allrem.com
Consystem S.r.l.
I-20144 Milano, ITALY
Tel: +39 02 4241471
Website: www.consystem.it
E-mail: support@consystem.it
Liquid
assets
2
1
Industry adoption
05/11/2014 15:56
Sixth
sense
As technology continues to advance, our reliance on and
relationship with machines deepens. This years LA Auto
Show Design Challenge explores how future engineering
innovations will transform human-machine interfaces
that connect with our senses, predict our next moves and
create a more human-like relationship with our vehicles, in
turn helping to realize a truly sustainable transportation network
ACURA
At the core of this entry is a human-machine interface
concept for Acura that comprises an exterior and interior
shell, connected through a modular adjustable mesh
material that can flex to suit a passengers preferences.
Able to accommodate one or two passengers, the interior
is constructed out of a fabric-like material that can be
altered simply by pushing or pulling on the surface. With
the help of biometrics and repeated use, this vehicle will
be able to learn the users preferences, anticipate their
needs and have the ability even to change its shape.
PETERBILT MOTORS
The SymbiotUX (pronounced symbiotics), is a concept
based on the projection that the future of transportation
will be dominated by a transformational shift toward
vehicles operating together in truly symbiotic
relationships that will, in turn, improve efficiency,
safety, wellness and travel enjoyment. An important
part of this transformation will be the role of the truck
driver, which will grow in stature and esteem, similar to
that of an airplane pilot. SymbiotUX is a design concept
that explores and illustrates how human-machine
interfaces will be transformed by this future reality. The
road pilot will have greater responsibility and therefore
the spaces and interfaces of a vehicle in pilot mode will
be purpose-driven to enhance pilot capabilities, leading
to energy efficiency, fewer accidents, less traffic
congestion and lower overall wear and tear.
TIRE RESEARCH
Reinventing
the
wheel
Parans Paranthaman
co-led the team of
scientists at Oak Ridge
National Laboratory
TIRE RESEARCH
advanced automotive
battery conference
Join us in 20l5
AABs
Tesla report
available
now!
AABC Europe
January 26 - 29, 2015
Mainz, Germany
AABC
June 15 - 19, 2015
Detroit, Michigan
www.advancedautobat.com
TIRE RESEARCH
Left: A comparison of
the nitrogen absorption
and pore volume of
graphite powder, control
carbon and tailored carbon
TIRE RESEARCH
Hazard warning
1. A transmission electron
microscopy image showing
control recovered carbon,
which has the morphology
of fused particles with
irregular shapes
2. Ground carbon produced
from the sulfonated tirerubber-derived monolith
has the morphology of a
uniaxial nanostructure
FRUGAL FORMULA
Motorsport has long served as a proving
ground for developing everyday tires. And in
this respect, Formula E, the worlds first fully
electric global racing series, has provided
the ideal opportunity for Michelin to further
improve the energy efficiency of its road
products as well as its production processes.
The French company was awarded the
contract as tire supplier to the championship
back in 2012, and it took just one year for the
team to develop the Michelin Pilot Sport EV
according to the FIAs technical requirements.
At the time, the layout of the tracks was
unknown and a final specification for the car
had not been finalized, which presented an
interesting challenge to the development team.
That was one area where we had to work with
the organizer, says Michelins motorsport
director, Pascal Couasnon. At least we knew
what would be punishing for the tire either
full speed under loads or at low speed and full
48V SpeedStart
www.cpowert.com
Intelligent electrification
for fuel economy
.....in the real world.
Thermally managed
for maximum duration
recuperation
HYBRID RACERS
Long-distance
The Toyota TS040 has consistently
been the fastest car in this years World
Endurance Championship. E&H got the
inside track on its digital development
runner
HYBRID RACERS
www.powermodules.danfoss.com
Build in
E-powertrain
efficiency
HYBRID RACERS
VS
HYBRID RACERS
1. A 60% model of TS030,
predecessor to Toyotas current
car, in one of TMGs two wind
tunnels. Both have continuous
steel-belt rolling roads with a
maximum speed of 70m/sec
2. A TS040 gearbox on the
transmission lubrication test
rig. By simulating the g-forces
and analyzing the oil flow, the
oil tank can be reduced in size
as less contingency is required
3. The Le Mans track, used
for the World Endurance
Championship, is available in
TMGs high-tech simulator
16
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li
4
1
0
e
v
e
at
in
fo
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ca
st
l
e
c
00
h/
W
0
40
k
h/
kg
h
ac
20
v
le
Solar Energy
Defence
Storage
info@oxisenergy.com
+44 (0)1865 407 017
www.oxisenergy.com
testing
by HBM
Optimized testing
of electric drives
Further information:
www.hbm.com/edrive
HBM Test and Measurement
info@uk.hbm.com www.hbm.com
Innovation by Tradition
Go to
commercial
Using a wealth of experience gained in the defense industry,
a global power electronics supplier is making strides
into the commercial hybrid market
Changing markets
COOLiRIGBT
35
30
25
CooliRIGBT
Gen 1
Tj = 175C
Tj max = 175C
20
15
10
Super Junction
MOSFET
Tj = 150C
Features:
5
0
1 kHz
10 kHz
100 kHz
COOLiR
COOL
iRIGB
iR
IGBT
IGB
T
COOLiRIGBT
Gen1
Tj Max
150C
175C
Manufacturability
Complex
Simple
Switching
Frequency
High
High
Losses At
High Currents
High
Low
1000 kHz
SkelCapTM ultracapacitors are 100 times more powerful than batteries and can be charged and
discharged in only a couple of second, making them perfect for high power applications, like for a
KERS system or for an acceleration boost system.
They can reliably and safely deliver over a million cycles even in extreme conditions with an
efficiency of 99%.
www.skeletontech.com
Supply and
demand
As consumer popularity continues to grow for
EVs and HEVs, car makers are facing tough new
challenges on an R&D level to meet market needs
WORDS: KARL VADASZFFY
HUBER+SUHNER, Inc.
19 Thompson Drive, US-Essex Jct., VT 05452/USA
HUBER+SUHNER AG
8330 Pfffikon/Switzerland, hubersuhner.com/automotive
HSI_E&H_Vehicle_Fullpage_EN_January.indd 1
02.10.2014 15:28:23
ELECTRIC MOBILITY
WITH INTELLIGENCE
BRUSA Elektronik AG
CH-9466 Sennwald
Switzerland
ENGINEERING
FOR ALL ASPECTS
OF HYBRID, ELECTRIC
AND FUEL CELL VEHICLES
Delivering Excellence Through Innovation & Technology
FROM TOTAL
HARDWARE SOLUTIONS
TO COMPLETE TURNKEY
VEHICLE PROJECTS
www.ricardo.com/hes
Figure 1 (above): A detailed graphic outlining an inverter consisting of a high-power IGBT module that in turn is
controlled by a logic device, which operates in the low-voltage (12V) battery domain. Figure 2 (below): The I/O monitor
of Infineons new AURIX microcontroller family compares the IGBT state with the original PWM command in real time
Figure 3: The above detailed information graphic showcases a prime example of an optimized inverter architecture
Clutches
Gearboxes
Driveshafts
Brakes
Controls
Electrics
Wheels
From
Power Source
To
Power Applied
The GKN Hub DrivE is an in-hub electric motor drive system with reduction gear and brake.
With an electric motor mounted at the heart of a wheel hub, electric motors are ideally
suited to in-hub off-highway electric applications. It is a compact unit, delivering optimum
efficiency and performance.
The AF-130/140/230 and 240 electric motors are three-phase permanent magnet motors
AF-electric motor
that use proprietary axial flux technology to deliver very high torque and power density in
a compact and light-weight unit. This makes them particularly suitable for use in electric
and hybrid vehicles, where low weight and compact packaging are important for delivering
optimum efficiency in performance and design.
GKN_IVT_Anzeige_215x275mm nov.indd 1
21.10.14 12:23
Founded in 1957, European leader in the production of manual transmission shift forks, FAVI is an automotive Tier1
supplier (ISO TS 16949 certified).
WITH MORE THAN 1.5 MILLION COPPER ROTORS ALREADY PRODUCED, FAVI IS YOUR RELIABLE PARTNER FOR THE
DEVELOPMENT AND PRODUCTION OF COPPER ROTORS.
Reluctance-assisted motors
The development of reluctance-assisted external rotor permanent magnet machines
could improve torque-speed ranges and further reduce the need for rare earth magnets
Until now, the main rotor
technology found inside
TM4s electric motors was based
on surface-mounted outer rotor
topology in which the magnets are
glued directly to a rigid carbon steel
rotor. However, in recent years,
uncertainty and higher prices of rare
earth magnetic materials, in
combination with the demand for
wider torque-speed operation
ranges, have resulted in a drive to
look for possible improvements in
existing technology.
It is well documented that the
reluctance torque in permanent
magnet machines can be used to
gain better performance. However,
introducing this concept in TM4s
outer rotor topology is a challenging
task, due to the thin rotor structure
found in the external rotor approach.
After a thorough development
process, TM4 overcame these
challenges and will introduce this
technology in 2015 as part of new
products offered in both its Motive
(light-duty vehicles) and Sumo
(commercial vehicles) electric
powertrain systems. Particularly of
note is the design procedure used
for the reluctance-assisted outer
rotor permanent magnet machine,
and a comparison of the new
machines performance against
a surface-mounted permanent
magnet machine of the same
dimensions.
Normally, the advantage of an
external rotor machine is its higher
air-gap radius, which leads to a
higher torque for the same magnetic
force. This technological choice was
made by TM4 when it first started
working on the in-wheel motor
technology developments that
ultimately led to the companys
creation, and was kept and
improved in subsequent products.
To maintain this advantage, the
thickness of the rotor should be
Reluctance-assisted external rotor permanent magnet machines can offer a greatly improved torque-speed range
Figure 2: A performance
comparison of the
permanent magnet motor
using the new reluctanceassisted outer rotor
technology, and the original
surface-mounted machine
Figure 1: A strip of lamination added to the rigid carbon still rotor satisfies saliency and rigidity requirements
PRODUCTION ELECTRONICS
www.mclaren.com/appliedtechnologies
xxxx
D2Ts test center in Trappes, where the company works to refine BMS functions
Implementing a mild hybrid system in truck applications offers potential fuel savings, but with far lower associated expense
The simulation of vehicle sound based purely on CAE models helps set development targets by enabling designers
and engineers to experience the NVH consequences of model updates on virtual vehicles in a free-driving scenario
SIMULATING SYSTEMS
FLOW THERMAL STRESS EMAG ELECTROCHEMISTRY CASTING OPTIMIZATION
REACTING CHEMISTRY VIBRO-ACOUSTICS MULTIDISCIPLINARY CO-SIMULATION
info@cd-adapco.com
www.cd-adapco.com
06/11/2014 10:51
High-voltage
interlock loop
High voltage
to drivetrain
High voltage to charger
Mechanical
interface
Protection
ground
interface
A virtual rechargeable energy storage system upon which all safety analysis for the safety device out of context is performed
Up to 250kVA
For electric and hybrid drive trains
Vbattery: 150V up to 800V
3-phase IGBT inverter
EMI compliant in accordance with 72/245/EWG
Sintered chips
Utility
Vehicles
Urban Transport
Equipment
www.semikron.com/contact
GROUP
EVO 11kW
Ultracapacitor storage
Efficient and suited to multiple applications, ultracapacitors can
be used to store energy captured during regenerative braking
During conventional braking,
kinetic energy from a cars
momentum is dissipated as heat.
Regenerative braking involves the
capture of this wasted energy. In
regenerative braking, the vehicle
system is designed to capture
braking (kinetic) energy by
regenerating it into electricity. This
electricity is then used to charge an
onboard energy system such as a
battery or an ultracapacitor. The
stored energy is used for vehicle
acceleration, thus reducing engine
load and increasing fuel economy.
Hybrid and electric vehicles
present an excellent example of the
use of regenerative braking. In these
systems, the electric motor is used
as both a motor and generator.
During propulsion, the electric
motor converts electrical energy to
mechanical. During regenerative
braking, the motor functions as a
generator, converting mechanical
energy into electrical, which charges
onboard ultracapacitors.
Regenerative energy capture is
growing in popularity. With todays
rising fuel prices and increasing
carbon emissions, all sectors of
transportation are searching for
ways to improve fuel efficiency.
The automotive, rail, bus and heavy
machinery industries are showing
significant improvements in fuel
economy with the introduction of
regenerative energy capture. Fuel
economy gains are much higher for
vehicles that make frequent stops
and starts, such as in-city driving.
Maxwell Technologies has been
collaborating with transportation
engineers and integrators to provide
ultracapacitor solutions for energy
capture. Although batteries have
been a traditional storage system
of choice, ultracapacitors are
gaining market share.
The biggest advantage of using
ultracapacitors for regenerative
American Maglev utilized Maxwell ultracapacitors for TriMet, resulting in reduced operating costs and energy consumption
number of power-hungry
applications in todays global
transportation markets.
Unlike batteries, Maxwell
ultracapacitor products store energy
in an electrical field. This enables
ultracapacitors to charge and
discharge in fractions of a second,
perform normally over a broad
temperature range (-40C to +65C),
operate reliably over hundreds of
thousands (or more) duty cycles,
and resist shock and vibration.
Maxwell offers ultracapacitor
cells ranging in capacitance from
1F to 3,400F, and modules ranging
from 16V to 160V, which have been
proven to deliver high power,
whether used alone or paired with
batteries, in a variety of applications
from automotive and transportation
to renewable energy or power
industrial electronics.
FREE READER INQUIRY SERVICE
To learn more about
Maxwell Technologies,
visit: www.ukipme.com/info/ev
Gold-plated resistors
A new family of resistors with gold-plated surfaces and contacts features
low-ohmic components that can be mounted with conductive adhesive
The new PMH-D and PLU
precision performance foil
resistors from Isabellenhtte are
a new type of resistor, featuring a
gold-plated surface. The VMx-A,
a member of the VMx precision
resistor family, has gold-plated
contacts. The PMH-D and PLU
bondable resistors are produced
using the Isa-Plan process, in which
layers of manganin foil, copper
substrate and an adhesive with
good thermal conductivity (ceramic
filled) are pressure bonded. This
highly temperature-resistant
bonded combination of substrate
and resistant foil ensures optimal
dissipation of heat. A small increase
in the temperature level of the
component has a positive effect on
stability and long-term drift.
Isabellenhttes all-new gold-plated
resistors can be mounted with
conductive adhesive, making all of
these resistor families well suited to
applications in the automotive
sector which involves high
temperature and load requirements.
They are certified according to the
AEC-Q200 quality standard for
electrical components.
The PMH-D (which measures 6.7
x 3.4 x 0.7mm) and the PLU (10.4 x
6.4 x 0.6mm) are designed for
hybrid mounting with bonding
technology. The bonding pads and
the back side of the component are
plated with a 0.1m layer of gold,
which makes soldering and
mounting with conductive adhesive
possible. The result is an ideal
thermal coupling that makes best
use of the available component
surface. The resistors are designed
to handle a constant load of up to
5W at 150C and a constant current
of up to 50A (PMH-D/size 2512) and
70A (PLU/size 3924). The PMH-D is
currently available as a 2m resistor
and the PLU as a 1m resistor.
Both resistors have been designed
Isabellenhttes gold-plated resistors can be mounted with conductive adhesive and are well suited to automotive applications
EV drivetrain control
Optimizing the drivetrain control strategy of inner-city electric delivery
vehicles can improve efficiency and battery life, and reduce cost of ownership
The growth of e-commerce
has increased the need for
fleets of delivery vehicles.
These vehicles, when powered
by combustion engines, operate
inefficiently in stop-and-start, innercity duty cycles. Local governments,
therefore, are encouraging the move
to electric delivery vehicles in most
inner cities.
When fleet managers are willing
to invest in an electric vehicle, they
are faced with the issue of total cost
of ownership despite incentives
that are available to offset the cost.
Typically, battery costs are high,
and anything that can be done to
optimize the size of the battery pack
according to the vehicles duty cycle,
or to extend the vehicles range, will
help accelerate the adoption of
cleaner, more sustainable
alternative transportation.
Actia Automotive has evaluated
the impact of the control strategy of
a permanent magnet motor on a
vehicles energy consumption
when used on these types of daily
routes. Specific control strategies,
optimized for an urban cycle, can
improve the battery pack autonomy
enabling downsizing of the
battery, increased operation range,
or prolonged battery life.
Modern magnet motors controls
are usually based on a vector PWM
Adopting a flexible SVM strategy can reduce overall electric drivetrain losses
Electrical
Architecture
Expertise
Power
Electronics
&
Battery
Systems
Manufacturing
Plants
Automotive
Quality
Standards
Zero-emissions motoring
The Formula E championship has the potential to accelerate research and
development in electric motoring to the benefit of the entire EV industry
Electric vehicles cars driven
by one or more electric
motors powered by batteries
recharged from an external
electricity supply now have a
global showcase. The official
Fdration Internationale de
lAutomobile single-seater Formula
E championship commenced in
September 2014 in Beijing, and
continues until June 2015. The
series will travel to 10 of the worlds
best-known cities (including
London, Miami, Buenos Aires,
Berlin and Monte Carlo) and
features 10 teams, each with two
drivers. Teams will compete using
the high-performance SparkRenault SRT_01E, with each driver
having two cars.
But Formula E is not just about
glamorizing EVs. Alejandro Agag,
CEO of Formula E Holdings, says
that the championship will become
the framework for research and
development around the electric
car, a key element for the future of
our cities. Just as other technologies
have been either invented or
perfected in motorsports and later
trickled down into conventional
vehicles, Formula E hopes to do the
same for EVs. To that end, leading
electronics distributor Mouser
Electronics is sponsoring the China
Racing Formula E Team. Joining the
sponsorship of China Racing are
electronic component companies
Vishay, a leading global supplier
of semiconductor and passive
components; and Molex, a leading
technology provider with a product
portfolio ranging from connectors to
cable assemblies.
Although the history of electric
vehicles can be traced back to at
least the 1830s, it is only in the past
20 years or so that leading global
manufacturers have directed proper
resources into intensive research
and development. And EVs are
China Racings Formula E racecar sponsored by technology suppliers Mouser, Vishay and Molex accelerates hard at the
inaugural championship event, which took place in September 2014 at the Beijing Olympic Green Circuit (Photo: Formula E)
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Flywheel-based KERS
A flywheel-based kinetic energy recovery system can offer many of the benefits
of hybridization in heavy-duty applications, but without the associated high costs
Having recently started
passenger-carrying trials with
operators, Torotraks Flybrid kinetic
energy recovery system (KERS)
aims to be the most cost-efficient
hybrid system for bus applications
on the market.
The innovative flywheel-based
unit is completely mechanical and,
due to its relatively common
components and materials,
promises to be considerably less
expensive than hybrid electric
options on the market. At around
one-third of the weight, a quarter of
the cost and with only a five-year
payback period, this newcomer
offers an affordable hybridization
alternative to the incumbent electric
solutions. Initially aimed at singledeck buses, the system is also
suitable for application in other
commercial vehicles.
The Flybrid KERS unit connects
to the rear axle of the single-deck
StreetLite midibus via a power takeoff (PTO) arrangement; this enables
it to transfer kinetic energy directly
away from the driveline to spin up
the flywheel and slow down the
bus. At only about 8kg, the flywheel
itself is the key ingredient of the
system spinning exceptionally fast
in a specially designed containment
housing, it can deliver up to 120kW
and 5,000Nm, on demand, to the
driveline of the bus. The specially
designed mechanical transmission
between the PTO and the flywheel
ensures that torque is delivered
smoothly during the storage and
release of energy, and provides
driveability and driver control
virtually identical to that of a
conventional diesel bus.
The Flybrid bus KERS unit is
the result of a two-year project in
partnership with bus manufacturer
Wrightbus, and while the prototype
units currently on fleet trial with
customers such as Arriva are
A KERS-equipped Wrightbus
StreetLite midibus at Cenex LCV 2014
the result of a two-year project
Multi-engine processors are required to meet the new and high demands of image recognition-based advanced driver systems
Lithium-sulfur batteries
An alternative to more common battery chemistries, lithium-sulfur has the potential
for use in electric vehicle applications, reducing range anxiety and improving safety
Much has been written about
lithium-sulfur (Li-S) in the last
couple of years, but it can be useful
to go back to basics and explain
this new battery technology.
At its heart, an Li-S pouch cell
comprises various layers of
materials, including a lithium metal
anode, a sulfur-based cathode
that includes carbon and a polymer
binder, and an electrolyte that
renders the cell safe.
This chemistry has several
important advantages over existing
technologies such as lithium-ion
(Li-ion), including addressing the
two largest challenges to the mass
adoption of electric vehicles: range
anxiety and safety.
Systems using metallic lithium are
known to offer the highest specific
energy and, coupled with sulfur,
offer an extremely high theoretical
specific energy five times that of
Li-ion. Readings in excess of
300Wh/kg have already been
demonstrated within commercialsize pouch cells. So for the same
energy stored, the battery will be
considerably lighter than Li-ion
(or indeed any battery chemistry
available). This means more
batteries of higher energy density
can be added to a vehicle,
increasing the distance it can travel.
With the improvements being made
to Li-S over time, vehicle journeys of
600-800km should be possible on
one charge.
Safety and reliability are both
guaranteed by the specific choice
of Li-S chemistry. Inherent in the
technology are two key mechanisms
that protect the cells a ceramic
lithium sulfide passivation layer and
a high-flashpoint electrolyte. This
means that the cell can survive a
barrage of electrical and physical
abuse, including puncture, without
any adverse reaction. Safety is seen
to be the major problem with Li-ion
Automotive EV cables
Electric motorcycles have become the latest vehicle type to enjoy the
benefits of shielded, reliable and highly resistant automotive power cables
Lito Green Motion electric motorcycles utilize high-performance Radox automotive cables (right) to connect the battery and motor systems in their advanced drivetrains
Multi-physics simulation
High-fidelity, multi-physics engineering simulations are advancing
the design and development of key hybrid components and systems
The changing engineering
simulation requirements
brought about by electric and hybrid
powertrain designs, as opposed to
conventional IC engines, have
provided a growth opportunity for
simulation companies. One of the
first to respond to such changing
needs was CD-adapco, an early
leader in engineering simulation
methods. The company launched
an ambitious extension of its
computational fluid dynamicscentric tool, STAR-CCM+, to add
multi-physics capability necessary
for the modeling of certain hybrid
system components.
First to be added was an
electrochemistry analysis device
that enabled design engineers to
understand the effect temperature
can have on installed battery pack
performance, as well as the effect
an electrical load can have on the
temperature of cells within such
packs. This coupled approach
has led to a flow, thermal and
electrochemistry solver being
developed, with notable projects
along the way, including those with
the Department of Energy (DoE) in
the USA and a consortium of
German car manufacturers. An
example of the possible results was
recently published at a DoE event,
which showed a simulation of a
Johnson Controls 12-cell model
during a PHEV drive cycle. The
simulation predicts temperature
fields as well as battery-specific
values such as cell voltage and
pack state-of-charge.
More recently, this technology has
been used in with other simulation
tools to highlight how critical cell
properties can be managed by
differing control strategies within
an overall vehicle or powertrain.
Another key component that
benefits from multi-physics
simulation is the traction motor.
A detailed cross-section showing temperature levels through a JCI 12-cell module during a PHEV drive cycle discharge
Sensor self-diagnostics
As the complexity of electronics in vehicles continues to increase, the ability
to have sensors perform self-testing can provide a vital early warning system
In todays highly innovative
and technological world, cars
have been designed with features
from high-tech navigational systems
to mood lighting. You can easily find
your location and even park
effortlessly using park-assist. But
what happens if you break down
on the way?
With so many of a vehicles
operations being driven by
electronics, manufacturers are
required to adhere to more and
more safety standards (ASIL and
ISO 26262, for example). Meeting
these criteria requires increased
failure mode analysis and
documentation during the design
process, and the implementation of
additional fault detection circuits on
all safety-critical designs. The goal
of this added complexity is to
diagnose a given problem before
it significantly affects the driver.
Lets consider the main vehicle
systems of a car. Whether its an
internal combustion engine or a
hybrid powertrain, there are
electronic sensors continually
monitoring the system during
vehicle operation. If a failure occurs
and operation is affected, a sensor
Figure 3: An on-chip coil excites the magnetic signal path and then provides a code
on the output pin indicating whether the chip operation has either passed or failed
The 3-speed, dry dual-clutch NexDrive EV3-850 transmission undergoing efficiency testing at Kinetics Drive Solutions facility
The SKF Rotor Positioning Sensor Bearing Unit has embedded sensor technology
MTU Friedrichshafen
MTU Friedrichshafen
functions to be
implemented in
levels up to SIL 2,
and defined the
shutdown of a battery pack
as a safe state. The BMS from
STW realizes these functions and
the company is able to provide
verification in accordance with the
applicable standards.
Each of the modules installed
in the battery includes a cell
supervision circuit (Figure 2).
Each pack is assigned two
contactors, which enable two-pole
switching of the respective battery
pack. These are supplemented by a
highly accurate, shunt-based
current measurement and insulation
monitoring, as well as a pre-charging
unit that enables controlled charging
of circuit capacitance.
In the case of parallel operation,
one BMS (as shown in Figure 3) is
assigned a master function. This
BMS assumes the coordination
role and makes the ESS appear
to be an individual battery with
correspondingly higher capability.
Testing and validation of the
functions of the ESS in interaction
Thermal insulation
Module
Hydraulic
Power connectors
Battery management
incl. main contactors
The eDrive allows users to analyze data in order to better understand the results
Space vector or dq0
transformations of
raw data enables
deeper insights
into inverter and
motor matching
Arbin Instrumentss
HRDT 30V-2, 500A
discharge system
and ignition
simulations. While
other systems may
use a water-cooled
testing solution that
requires auxiliary
facilities, the aircooled design of
the HRDT allows
for compact floor
space and does
not require a
separate cooling
system. Each
machine is modular
and customizable
with current ranging
up to 3,000A and
power rating up to
120kW. The photo
shows an example of
a 2,500A discharge, 1,000A
charge, 30V system. Each channel
on the cold crank testing device
comes with a variety of auxiliary
inputs to offer the user optional
features, such as monitoring cell
voltages, monitoring temperature,
CANbus communication and more.
The HRDT products also
contain multiple layers of fusing
and safety parameters to protect
the device under test and
hardware, such as Arbins
signature voltage clamp circuitry,
which helps to prevent dangerous
overcharging and discharging.
Flexible chargers
A new series of energy-dense battery chargers will be able to connect to all power
grids across the world, thanks to the inclusion of a universal AC input voltage converter
Ironclad batteries include an electrolyte with higher than average specific gravity
Drivetrain ultracapacitors
Ultracapacitors offer high power and energy density, together with low levels of resistance,
and make for a very reliable and compact technology solution for electrified drivetrain systems
Figure 1: The
standard hybrid
EV power
and control
architecture
Figure 2: The
simplified hybrid
EV power control
architecture with
a single FPGA
LEONI Hivocar
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More.
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DESIGN FLEXIBILITY
C O N TA C T R E L I A B I L I T Y
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2015
11.864
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www.ecartec.com
Exhibitors
82%
Trade Visitor
71%
Decision
Makers
51%
Engineering
Visitors
generations of semiconductors
can now be used without facing
the restrictions that are typical of
traditional soldering and aluminum
wire bonding.
This new bonding and joining
technology provides customers with
a previously unavailable opportunity
to choose between cost-efficiency,
compactness and current capability,
depending on application and
preferences. Danfoss Silicon Power
is currently ready for volumeproduction of this next generation of
power modules.
FREE READER INQUIRY SERVICE
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To obtain measurements of
energy consumption under different
conditions (such as varying speeds
or gradients), a GPS sensor also
logs the vehicle position, noting
altitude, speed and acceleration of
the electric car using the same
measuring system as, and recording
synchronously with, the energy
consumption data. In parallel, a
video camera connected to the
measuring system films the test.
The architecture of Dewetron
systems records data synchronously
from many sources and stores it
together. The data analysis and
processing is faster and easier than
other approaches, since all data is
automatically correlated. This offers
new possibilities for comparing
results and understanding test data.
FREE READER INQUIRY SERVICE
To learn more about Dewetron,
visit: www.ukipme.com/info/ev
Conformal coatings
For over 40 years, Parylene conformal
coatings have provided automotive electronics
and components with a level of protection that,
even today, remains unmatched by most coating
materials. Parylenes offer excellent moisture,
chemical and dielectric barrier capabilities,
superior thermal and UV stability, and a low
coefficient of friction.
Parylene coatings are applied in a vapor
deposition polymerization process. Because
there is no liquid phase in this process, there
are no subsequent meniscus, pooling or
bridging effects, thus dielectric properties are
never compromised. The molecular growth of
Parylene coatings also ensures not only an even,
conformal coating at the thickness specified by
the manufacturer, but because Parylene is formed
Engine downsizing
through charge boosting is
a well-understood means of
improving ICE fuel efficiency
by increasing the proportion
of the drive cycle at which the
powertrain operates within
or close to the region of peak
fuel efficiency of its operating
map. The limitations of
downsizing, however, include
the delivery of acceptable
driveability characteristics
and launch performance.
Full hybridization provides
a means of energy
management that mitigates
such shortcomings, but at a
considerable cost premium
associated with the electrified
powertrain architecture,
including the high-capacity
battery and electric motors.
For the Advanced Diesel
Electric Powertrain (ADEPT)
project, Ricardo is leading
a six-partner consortium
which also includes Ford
Motor Company, Control
Power Technologies (CPT),
European Advanced Lead
Acid Battery Consortium
(EALABC), Faurecia
Emissions Control
Technologies UK and the
University of Nottingham
to reapply the intelligent
electrification concept
theme to a diesel vehicle (a
Ford Focus estate) for the
first time. The project will
evaluate benefits derived
Trineuron is a fast-growing
division of Emrol, a well-known
Belgian battery specialist
that was founded in 1981. The
company supports applications
requiring electric energy storage,
energy conversion and energy
management, working with a
range of customers on projects
around the world.
FREE READER INQUIRY SERVICE
To learn more about Trineuron,
visit: www.ukipme.com/info/ev
INDEX TO ADVERTISERS
INDUSTRY FOCUSED
SERVICE-MINDED
Innovation n0033
EM I SSI O N
EF F I C I E N CY
EMPOS
ROTOR POSITION
SENSOR FOR EV
AND HEV APPLICATIONS
This embedded
smart sensor is
based on Eddy
curent technology
Infineon ..................................................2
Arbin Instruments..............................15
AVL ........................................................ 5
Bergquist ............................................65
Kolektor ..............................................40
Bitrode ................................................ 24
Lear Corporation...............................43
BorgWarner .......................................33
CD-adapco ........................................157
Maccor ................................................49
Controlled Power
Dewetron.......................................... 163
by
This EMPOS embedded smart sensor optimizes the efficiency of electric motors and
GREEN
hybrid
engine management.
DESIGNED
by
EMPOS is not affected by the harsh magnetic environment of hybrid drives and
electric vehicles.
Technology International.................31
Schaeffler........................................... 97
EnerSys .............................................. 73
Sensor-Technik .................................40
EVWorld.com.................................. 194
TM4 ......................................................10
EFI Automotive
Flybrid.................................................55
Toshiba ...............................................29
Trineuron ............................................55
UQM Technologies........................... 70
Heinzinger.........................................197
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