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E-Mobility E-Mobility E-Mobility ENGINEERING The communicaTions hub of The elecT E-Mobility Train ENGINEERINGTrain Train rified powerTrain rified power rified power Tions hub of The elecT rified power he elecT The communica heENGINEERING elecT Tions hub of T ENGINEERINGTions hub of T The communica ICE-breaker The communica Model ofBulk productionHow the Lightning Strike motorcycle competes Current Silent FlightPipistrel Alpha Electro Development details of the 944Kwith Hybrid the old Wheel guard Loader on performance and cost assets Focus on inverters Uniti’s bold EV concept 48V DisruptorVolabo’s ISCADsustainability in detail

Thermal management Taking thetechnology Heat investigated

UK £18 UK £18 USA $30 Talk the torque €22 USA $30 UK £15 EUropE €22 UK £15 EUropE USA $30 USA $30 EU The advantages – and challenges – EUropE €22 ropE €22 Axial of axial flux motor technology

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ambition | Phi-Power’s PHI 301 in detail Direct action Deep insight: hydrogen-powered vehicles

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ISSUE 004 could be a game-changer 003 ISSUE

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MATERIALS

The The Bell Nexus air taxi will have a range of 150 miles (Courtesy of Bell Helicopter) New-gen composites on show Grid such as suspension members or other Stiffness is naturally an important Lightweight materials are a key element design constraint to ensure a consistent of the integrated engineering approach highly loaded parts, continuous fibres airgap is maintained. Efficiency savings needed for EV vehicle development, as are used. “That gives you very high were twofold – overall package weight engineers strive to reduce vehicle weight specific strength with directional control was reduced, as were the inertia and in order to increase the effectiveness over the fibres as well,” said Thompson. thus parasitic losses. of the battery energy available (writes Particle reinforcement is used for Another attractive property of the Lawrence Butcher). A new generation complex shapes, allowing more Alvant materials is their coefficient of of materials developed by UK-based complex geometries to be formed. thermal expansion, which is lower than Alvant provide an interesting option for One interesting string to Alvant’s that of aluminium. This could be a engineers engaged in such projects. bow is its syntactic foam product, significant benefit in motor applications Alvant specialises in aluminium which is an ultra-lightweight aluminium, as well as areas such as battery matrix composite (AMC) materials full of tiny spherical voids within the structures. The low thermal expansion and, importantly, in developing aluminium. It can be used in a similar is due to the reinforcing fibres, which methods to allow their practical use in way to honeycomb core material in constrain the growth of the material. manufacturing. carbon fibre composites, providing The light weight and temperature “In essence, we take aluminium and internal structure to a part without resistance of the materials make them combine it with a secondary high- increasing mass to the same degree as a viable replacement for composites, performance reinforcement material, a solid filler material. providing much of the weight saving THE CONTENT either in the form of particles or Sandwich materials are not a new THE CIRCULATION without any reduction in mechanical fibres,” explained Richard Thompson, idea, but generally they are assembled, properties at temperatures above commercial director at Alvant whereas Alvant’s CorXal material – carbon composite thresholds. The fact “That allows us to create materials the brand name for its composite of that the materials’ matrix is aluminium, with superior performance to traditional syntactic foam and fibre-reinforced rather than a resin, also means it retains metallic materials such as aluminium aluminium combination – is a high thermal conductivity – an important HYBRIDS alloys, high-strength steels and titanium homogenous structure that is produced aspect in applications such as motors alloys.” Alvant’s tag line is ‘the strength in a single process. or batteries, where directly cooling parts of steel with the weight of aluminium’. “The density we can achieve with it 3 can be a challenge. Bell flags up electric air cab Components made with Alvant’s is around 1.5 g/cm , similar to some materials are created using a proprietary carbon composites but with greatly development and production of batteries is controlled by a hybrid An electric motor rotor made using Alvant Launched in 2018, EME Bell Helicopter, part of the group, process called advanced liquid pressure improved stiffness and strength over material (Courtesy of Alvant) power controller. has unveiled its design for an air taxi the VTOL systems, while Safran will unreinforced aluminium,” Thompson Safran ran ground tests of its forming. This process is flexible and using a hybrid electric propulsion unit provide a hybrid power and propulsion said. “The skin portion of the material distributed power system in mid-2018, can create net-shape parts or billets, (writes Nick Flaherty). system. features a continuous fibre, while the with the test using a 100 kW output depending on the specification, the aim The Nexus, launched at this year’s Details of the propulsion system core is made from the syntactic system running four electric motors. At being for it to be as close to the finished Consumer Electronics Show in January, and battery capacity have not yet foam, which greatly reduces the is the first publication to the time, Safran suggested a to-market dimensions as possible, in order to THE GRID been released, but information about uses six, 8 ft diameter ‘e-propellers’ that density.” date of 2025, which ties in with Bell’s reduce follow-on machining operations. E-Mobility Engineering magazine is read by engineers can be directed vertically or horizontally. Safran’s hybrid drives is available. The Of particular interest to the target of 2023 for flight testing the That is quite different from the way It is based on Bell’s experience with drive relies on a gas turbine to generate EV industry is a project Alvant Nexus. metal matrix composites (MMCs) designing and building the V-22 Osprey power, coupled to a battery pack recently completed with a In addition to Safran, EPS is creating have been used in the past, where the and V-280 Valor tiltrotor aircraft. which, according to Safran, can act as customer – producing a motor the custom battery packs with a starting point was a billet of material focus entirely on providing The 6000 lb Nexus will be built from either the main or an additional power rotor using its materials. “We that was machined to shape, resulting source, depending on the phases of containment system for each cell around the world actively working on developing technological The EME news section is focused on technological carbon fibre. It will carry four passengers in a high degree of (expensive) material targeted the rotor and, using flight. that will keep fires from spreading in and a pilot, and have a 150-mile range wastage. selective reinforcement of the rotor For example, during take-off, where the event of a short-circuit. Thales is with a top speed of 150 mph. The specific application dictates with an MMC, we were able to reduce maximum power is required, both the providing the flight control computer The Nexus will include technology the reinforcement type used and the its weight by 40% while retaining batteries and gas turbine could provide hardware and software, while Moog independent coverage of from Bell, Safran, Electric Power distribution of reinforcement within a the required stiffness,” said power to the motors. The power will oversee development of the flight Systems (EPS), Thales, Moog and part. For example, for structural parts Thompson. solutions for electric vehicles and the systems that support development. Business and politics are only control actuation systems. Garmin. Bell is to lead the design, balance between the turbine and the

7 Spring 2019 | E-Mobility Engineering Spring 2019 | E-Mobility Engineering the engineering of electric 6 21/02/2019 10:12 covered in so far as they impact directly on 21/02/2019 10:11 EME002_The Grid.indd 7 them. Written by engineers, for engineers. EME002_The Grid.indd 6 vehicles. Published quarterly engineering solutions. From the outset EME has EME probes today’s cutting established itself as a publication that deals in hard science. CORE CIRCULATION READERSHIP edge projects to provide individually (average 3 in-depth research insights, DOSSIERS 6,000 mailed copies 18,000 readers per copy) rigorous investigation EME dossiers offer an incredibly detailed look at high backed by professional peer Insight | Uniti One profile E-Mobility projects, revealing many secrets of Start-up’s READERS INCLUDE: review and critical analysis. the technology that are simply not reported anywhere standing start • Chief Engineer • PHEV Engineer else. Our overall vehicle dossiers cover concepts Lawrence Butcher reports on how a Swedish start-up plans to design and manufacture a EME is an invaluable market-ready EV from the ground up • CTO • BEV Engineer from automotive, off-highway, aerospace and f one looks across the automotive EV market, it seems barely a week It should be noted that, as of the start goes by without one company of 2019, Uniti had not built a single Ior another announcing that it production or even an engineering will revolutionise the electrification of prototype of one. It had however • E-Mobility Engineer • HEV Engineer resource of actionable vehicles and unveils a host of sharp completed prototyping work on an earlier commercial applications. Each powerplant dossier design renderings. The vehicle in concept of the vehicle, and was deep question invariably takes the form of a into an engineering feasibility study of hypercar or SUV. what would become its launch vehicle. However, such concepts, while bold, intelligence for engineers are probably not the easiest way to From concept to reality • Modelling & Simulation • E-Drive Engineer explores in depth one of the diverse innovative enter the EV market, which is already The Uniti One is a compact, two-seat saturated by new-tech companies EV, with a 1+1 seating layout (where the such as Tesla, and established passenger is seated behind the driver). automotive manufacturers which are To gain a proper understanding of the whilst also providing a starting to ramp up EV production to Uniti project, it is worth looking briefly at Engineer • E-Propulsion Engineer significant levels. its background. power units at the forefront of today’s electric A more realistic approach could be that being taken by Swedish start- Uniti’s plan is to produce a compact and affordable EV aimed primarily at city users (Courtesy of Uniti) up Uniti, with its Uniti One project. The concept is a seemingly obvious The brainchild of Swedish targeted promotional one – pick the market area where • Design Engineer • Powertrain Engineer entrepreneur Lewis Horne, its roots based around the requirements for an EV currently makes the most revolution. lie in an innovation project undertaken a quadricycle, but with European the implementation of a lightweight, sense, the city car sector, and build a at Lund University, Sweden. The initial regulations due to change in 2020, the composite chassis. small, lightweight vehicle that meets concept for the Uniti was to be an L7E quadricycle route is no longer viable the needs of urban mobility at a The intention is ultimately for the class vehicle, otherwise known as a in the long term. The Uniti One is Uniti platform to be easily adaptable reasonable cost. Also, by not having an • Electronic Design Engineer • Drivetrain Engineer platform for those with quadricycle. That would put the car in therefore being upgraded to match the to different roles in a city environment, existing manufacturing infrastructure, the same class as vehicles such as the requirements of M1 homologation – a be that the use of a body variant to it can harness the latest advances Renault Twizzy. significant engineering undertaking. create a light goods vehicle or perhaps in manufacturing technology to In short, and in Europe at least, To achieve that, Uniti has enlisted the a version whose only role is to provide ensure lean, efficient and importantly, quadricycles do not have to pass the help of two companies to undertake remote charging for other vehicles. sustainable production. products and services of same stringent certification that M1 this phase of the vehicle’s development “If you look at the size of the platform, • Heads of Engineering • Electronic Engineer DEEP INSIGHTS A rendering of the initial Uniti concept (Courtesy of Uniti) class do, making it far simpler to – Danecca, a specialist in battery and there is so much scope to diversify 16 put one into production. The Uniti’s powertrain engineering, and KW Special into other uses and solve inner-city initial concepts and prototypes were Projects, which is working on the wider transport issues,” says Horne, who is vehicle engineering concept, including Spring 2019 | E-Mobility Engineering Uniti’s CEO. Here, the use of a 1+1 EME002_Insight Uniti One.indd 16 seating layout has the benefit of interest to them. If you E-Mobility Engineering’s ‘Insights’ drill down into Spring 2019 | E-Mobility Engineering • Heads of E-Mobility • Senior Engineer 21/02/2019 10:01 EME002_Insight Uniti One.indd 17 17

want to seize more than specific technological topics, providing mission 21/02/2019 10:01 • R&D Engineer • Hybrid Engineer your fair share of the fresh critical information for engineers working in the field. This may be a deep dive • Heads of R&D • Technical Director opportunities being created into high-power semi-conductor materials, through to an investigation into the challenges of • Project Manager • Engineering Director in this exciting market, then hydrogen infrastructure. The running theme being unmatched insight and technical detail. • Project Engineer EME is a must. 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 • Composites • Superconducting Magnetic • Harnesses, Connectors ENGINEERINGTrain he elecTrified power The communicaTions hub of T • Cooling Systems Energy Storage & Protection/Distribution • Motors • AC & DC Charging Systems Devices ICE-breaker Current How the Lightning Strike motorcycle competes • Cabling & Connectors • Power Electronics • Wireless Power Transfer with the old guard on performance and cost assets Focus on inverters • Additive Layer Subsystems • Stationary Wireless Power Manufacturing • 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

EUropE €22 • Fuel Cells • Sensors for Motors & • Materials

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Deep insight: hydrogen-powered vehicles 004 ISSUE

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www.eme-magazine.com SCHEDULE & CONTENTS

Issue Copy Deadline Publication Date Product Focus Tech Focus Bonus Distribution

EME 5 20/11/2019 06/12/2019 Lightweight Materials Radial Flux Motors CES / CWIEME Shanghai

EME 6 12/02/2020 28/02/2020 E-Axles Magnetics EV Tech Expo EU / The Battery Show EU / Revolution 2020 / CWIEME Berlin

EME 7 13/05/2020 29/05/2020 ECU’s Fuel Cells EVS 33 / iVT Expo

EME 8 12/08/2020 28/08/2020 Measuring Methods Chargers EV Tech Expo NA / The Battery Show NA / & Equipment Cenex-LCV / IAA 2020 / CWIEME Americas

EME 9 11/11/2020 27/11/2020 DC-DC Converters Battery Materials CES / CWIEME Shanghai

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