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EME002_Cover.indd 1 E-MOBILITY 10/10/2018 10:58 ENGINEERING EME001_Cover.indd 2 E-Mobility THE COMMUNICATIONS HUB OF THE ELECTRIFIED POWERTRAIN Train rified power he elecT ENGINEERINGTions hub of T E-MOBILITY The communica Wheels Developmentwithin details of ENGINEERING wheels Elaphe’s latest in-wheel motor THE COMMUNICATIONS HUB OF THE ELECTRIFIED POWERTRAIN How to beat the traffic Have a The technology behind the BB Green A fruitful safe trip electric ferry for commuters outcome Onboard chargers – the way to go? Dynium Robot’s fresh take on an autonomous electric tractor IN PRINT, ONLINE AND IN PERSON

UK £15 USA $30

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How to use lightweight materials 20/12/2019 13:34 to help extend the range of EVs

EME005_Cover.indd 1 The Grid

The POWER CONTROL All-in one unit for electric drives The DC power rails and FTCAP in Germany has developed Integrating the unit, and connecting the Grid capacitor directly to the heat sink, enables corresponding connections are and manufactured a low-inductance integrated in the capacitor and capacitor unit that, together with a heat a compact design measuring 29 x 21 cm. protected by joint potting, so only sink and housing, forms an integrated The 18 mm-wide polypropylene film is one external DC connection is electromechanical device for high-efficiency 2.4 μm thick, and the wedge-shaped zinc necessary. electric drives (writes Nick Flaherty). coating developed for the project has a The short electrical connections to The development is part of the H3Top resistance that varies from 3 Ω to 37 Ω. the power semiconductors enable project in collaboration with Robert Bosch, The design uses two capacitors a low-inductance connection for Infineon Technologies, Daimler and Aachen in series, each with a capacitance of the high (100-plus kHz) switching University to develop a DC-link capacitor 630 μF and a rated voltage of 450 V frequencies used by SiC devices. for next-generation EVs. The design uses DC. Other requirements included 12 or power modules, The winding achieves a a narrow, zinc-plated polypropylene film connecting terminals f capacitance of 78.75 µF in a single winding to minimise the internal resistance, direct connection of the heat sink, and unit. Two windings are connected reducing power losses by 20% in EVs distribution of the DC voltage via internal in parallel within one bank to give a operating at 800 V rather than today’s 400 V. power rails. “We developed different concepts in capacitance of 2 x 157.5 µF. For the The Morphoz concept design can be extended coordination with the project partners entire capacitor, which consists of at the front to add an extra battery pack that fulfilled the various individual four parallel connected banks, the capacitance is 2 x 630 µF. ELECTRIC CARS requirements,” said Andre Tausche, THE CONTENT managing director of FTCAP. Potting the heat sink with the THE CIRCULATION “On the basis of different simulations windings makes it possible to attach Long trip? Make the car longer and load profiles, we finally chose a model the semiconductor modules directly in which all the capacitor modules are to the heat sink, but still in the vicinity he said. “The CMF-EV can has developed a ‘shapeshifting’ the compartment and the batteries on the same level. That simplifies the of the capacitor. In addition, the thus be used in EVs designed electric car that becomes longer to are in the floor. This also gives more mechanical design and assembly.” connection and distribution of the DC predominantly for everyday allow an additional battery pack to be room in the passenger compartment. The integrated design means the DC voltage was achieved for the first time suburban trips, as well as those added (writes Nick Flaherty). The weight of the extra battery over voltage distribution can be achieved using flexible power rails that were capable of making long journeys The DC-link capacitor unit for 800 V drive systems IN PRINT, ONLINE AND IN PERSON the front axle helps to compensate within the capacitor. specially developed for this project. The 4.4 m-long ‘City’ version of the s without needing to recharge. includes a heat sink for SiC transistor Morphoz has a 40 kWh battery pack for the extra length. Being a concept “Compared to a traditional that gives it a range of 400 km. This vehicle, however, this design would POWER CONTROL platform, there is more space with would be suitable for 90% of local still be subject to crash tests. regards to the size of the motor journeys that drivers typically take, The second development is the compartment, plus the parts for Renault said. Common Module Family (CMF-EV) Three-phase SiC module cuts losses modular electric platform, which will an electric motor are also more to 10 A and immunity to the effects of For the 10% of longer journeys, Cissoid in Belgium has launched a of three compared with the latest silicon be shared across , Renault and compact than those in a diesel- or high-speed switching voltages of more drivers would take the car to a special three-phase water-cooled SiC MOSFET IGBT modules. Mitsubishi vehicles. This allows battery gas-powered car. than 50 KV/µs enable fast switching of ‘travel station’ for it to be lengthened intelligent power module (IPM) for The module is water-cooled through THE GRID packs of different heights to be used “Alongside the platform, we the power module and low switching to 4.8 m and an extra battery with a e-mobility (writes Nick Flaherty). a lightweight AlSiC pin-fin baseplate for E-Mobility Engineering magazine is read by engineers in vehicle have created an innovative heat capacity of 50 kWh inserted via a flap across multiple vehicle designs. a junction-to-fluid thermal resistance losses. management system for the The 1200 V/450 A module has built-in in the floor, in a process that takes just The platform also allows two of 0.15 C/W. It is rated for junction “Developing and optimising fast- Launched in 2018, EME battery. The difference in range gate drivers, and is designed to optimise successive generations of vehicle switching SiC power modules and a few seconds. This extends the range the electrical, mechanical and thermal temperatures up to 175 C, and to be created, making it key to new and charging time between driving them reliably remains a to 700 km, bearing in mind the vehicle design of the power module and control withstands isolation voltages of up to models for at least a decade, said summer and winter temperatures, challenge,” said Dave Hutton, CEO of would then be heavier and travelling at for electric car OEMs and electric motor 3600 V (50 Hz, 1 minute). Jean-Paul Drai, engineering director which we noticed on previous Cissoid. “This one is the outcome of OEMs, Tier 1 & 2 suppliers around the world actively working on The EME news section is focused on technological motorway speeds. manufacturers looking to adopt SiC- The gate drivers include three of electric vehicle projects for Groupe generations of EVs, is now years of experience in developing power The concept design is possible based inverters. onboard isolated power supplies (one is the first publication to Renault. drastically reduced. modules and gate drivers for extreme as a result of two main engineering The IPM has an RDS(on) resistance per phase) delivering up to 5 W each “The platform is of course also A new family of Renault electric temperature and voltage environments, developments. The extension happens of 3.25 mΩ with 8.3 mJ turn-on and to drive the power module at up to modular in its length, so we can models based on the CMF-EV and we are now delivering our first IPM at the front of the vehicle from the 11.2 mJ turn-off energies at 600 V/300 A. 25 kHz and at ambient temperatures of further tailor the battery to the type platform will be launched next samples to early SiC adopters.” A-pillar, ahead of the wheelbase, as This reduces losses by at least a factor up to 125 C. A peak gate current of up developing technological solutions for electric vehicles and the development. Business and politics are only year. there is no longer a heavy engine in of vehicle and the desired range,” focus entirely on providing 7 Autumn 2020 | E-Mobility Engineering Autumn 2020 | E-Mobility Engineering 6

14/08/2020 09:22 covered in so far as they impact directly on 14/08/2020 09:22 EME007_The Grid.indd 7 systems that support them. Written by engineers, for engineers. independent coverage of EME007_The Grid.indd 6 the engineering of electric engineering solutions. From the outset EME has vehicles. Published quarterly established itself as a publication that deals in hard science. CORE CIRCULATION READERSHIP EME probes today’s cutting individually (average 3 DOSSIERS edge projects to provide 6,000 mailed copies 18,000 readers per copy) in-depth research insights, EME dossiers offer an incredibly detailed look at high rigorous investigation profile E-Mobility projects, revealing many secrets of READERS INCLUDE: backed by professional peer the technology that are simply not reported anywhere • Chief Engineer • PHEV Engineer review and critical analysis. else. Our overall vehicle dossiers cover concepts Applications for the L1500 in-wheel motor include Sportscars (above), pick-up trucks, SUVs and urban vehicles (right), among others (Images courtesy of Elaphe Propulsion Technologies) • CTO • BEV Engineer from automotive, off-highway, aerospace and motors have some architectural • E-Mobility Engineer • HEV Engineer similarities. Fit for developed in-house, and it attaches commercial applications. Each powerplant dossier Wherever possible, Elaphe has directly to the vehicle knuckle. A systems (of which a range exists), sought to minimise the L1500’s weight. As a leading content traditional friction brake, with a disc including standardised brake rotors, As a result, each customer’s motor As a result, the ‘active part’ of the rotor and caliper, fits inside the stator calipers and electronic parking can be customised to a degree to motor – the electric machine with ring and attaches to the hub, as in all brakes. modify the rotor and stator interfaces windings and magnets – takes up • Modelling & Simulation • E-Drive Engineer duty cars these days. The described assembly of rotor, to accommodate their preferences in just 30% of the overall weight, giving explores in depth one of the diverse innovative The L1500 has been designed to enable it to be used in a Ease of integration and component stator, brakes and bearing transfers peripheral components such as the it a torque density of 460 Nm/litre, wide range of OEM EVs and HEVs. reports logistics have also been strongly loads from the road (which will vary brakes, bearings and other internal provider we understand that Rory Jackson compared with what the company cites prioritised by Elaphe during its design depending on vehicle weight, braking parts. on how it was developed as its nearest competitor at 390 Nm/ of the L1500. As a result, all wheel dynamics, cornering and ground Those parts are also kept as litre. It also has a torque-to-weight ratio integrations using the motor will also roughness) directly to the vehicle accessible as they would be in Engineer • E-Propulsion Engineer of 100 Nm/kg; its competitors go up to incorporate standard, off-the-shelf knuckle via the bearing, protecting the conventional road vehicles (and thus power units at the forefront of today’s electric 65 Nm/kg, Elaphe says. lovenian company Elaphe automotive bearings and braking electric motor components from such easily serviceable) thanks to the is known in the e-mobility L1500, a radial flux, three-phase AC The L1500 has 83 components, nearly our readers need access to impact loads. company’s approach to integration, in industry for its in-wheel synchronous motor weighing 33.3 kg, 60% of which are standard supplier which the motor is mounted over the propulsion technology, which with a radius of 23.2 cm (and therefore parts and the rest mostly casting or S brake assembly, similarly to the rim is used in a range of automotive fitting a standard 19 in rim) and an customised supplier solutions. • Design Engineer • Powertrain Engineer and tyre. revolution. applications around the world. axial length of 14.22 cm. At a nominal The system is configured as a direct- “The L1500 motors ar Established in 2006 by theoretical voltage input of 370 V, its maximum drive outrunner (meaning it has an e therefore simply inserted between the electric [or unbiased technical insight physicists Andrej Detela and Gorazd power output is 113.6 kW (at a speed external rotor and an internal stator). hybrid] vehicle’s hubs and rims, which Lampic (now the CEO), its systems of 1480 rpm), as well as a maximum The motor’s aluminium rotor case makes use of the existing space within incorporate a host of patented and tested torque of 1500 Nm. contains the yoke and permanent • Electronic Design Engineer • Drivetrain Engineer the wheel without needing to alter any proprietary technologies across Unveiled in 2019, the L1500’s magnets, the case wraps around the suspension or steering packaging on mechanics, electromagnetics and other design was based in the early stages stator, and is connected to the vehicle the platform,” explains Elaphe’s CTO so all of the articles are disciplines. of its development on the M700. The knuckle by a conventional automotive Gorazd Gotovac. At the top of Elaphe’s in-wheel M700 was the first motor Elaphe wheel hub bearing. Within 5 minutes the L1500 can be propulsion product range is the fully validated according to existing The stator ring is made from integrated into or removed from a car Elaphe integrates (from left to right) • Heads of Engineering • Electronic Engineer DEEP INSIGHTS automotive standards, and both magnetic steel laminations. Its poles standard-issue tyres with 19 in rims, wheel for routine maintenance, such as use a patented winding method 20 the L1500 housing (and rotor), its stator, brake inspections and replacements. standard automotive brakes and a standard In addition to being able to available in our traditional bearing, to mount to the vehicle knuckle Autumn 2020 | E-Mobility Engineering customise the in-wheel electric motor EME007_Dossier Elaphe.indd 20 for carmakers’ preferred brake E-Mobility Engineering’s ‘Insights’ drill down into Autumn 2020 | E-Mobility Engineering • Heads of E-Mobility • Senior Engineer 17/08/2020 14:00 EME007_Dossier Elaphe.indd 21 print magazine, digital 21

17/08/2020 14:01 • R&D Engineer • Hybrid Engineer magazine and blog style specific technological topics, providing mission • Heads of R&D • Technical Director articles so regardless of critical information for engineers working in the field. This may be a deep dive • Project Manager • Engineering Director how the engineers prefer to into high-power semi-conductor materials, through to an investigation into the challenges of • Project Engineer read the articles we have the hydrogen infrastructure. The running theme being unmatched insight and technical detail. formats to suit their needs. FOCUS In addition to the CEOs, COOs and Managing Directors of the global E-Mobility engineering community. Revisited just once every 2-3 years the ‘Focus’ acts as an excellent source of reference on E-MOBILITY specific products and types of engineering service – topics covered include: GEOGRAPHICAL BREAKDOWN ENGINEERING • Composites • Superconducting Magnetic • Harnesses, Connectors THE COMMUNICATIONS HUB OF THE ELECTRIFIED POWERTRAIN • Cooling Systems Energy Storage & Protection/Distribution Wheels within • Motors • AC & DC Charging Systems Devices Development details of • Cabling & Connectors • Power Electronics • Wireless Power Transfer wheels Elaphe’s latest in-wheel motor • Additive Layer Subsystems • Stationary Wireless Power • Power Semiconductor Transfer • Control Systems Devices & Highly Integrated • Dynamic Wireless Power • Inverters Modules Transfer • USA • Converters • Wide Band Gap Devices & • Wireless High Power Transfer • UK • Thermal Management Related Issues • Electromagnetic • Rest of Europe • Batteries • Packaging, Cooling & Heat Compatibility • Rest of World • Battery Monitoring/ Transfer • Modelling & Simulation Management • Magnetics, Capacitors, Bus • Measuring Methods & • Infrastructure Bar & 3D Integrations Equipment UK £15 USA $30 Brain EUROPE €22

surgery Stop interfering • Fuel Cells • Sensors for Motors & • Materials AUTUMN 2020 AUTUMN

The sources of EMI and | The anatomy of the how to mitigate it • Supercapacitors Converters • Test Systems

modern ECU revealed ISSUE 007 ISSUE

14/08/2020 09:24

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