Wednesday, December 7, 2022

The importance of components: pre-integrated system solutions

Fab, Waver, semiconductor, factory, industry, RB 300, automotive, car electronic, Robert Bosch Semiconductor Manufacturing Dresden GmbH, Deutschland, Germany, Silikon Saxony, Dresden, © 2021 Baldauf und Baldauf für Bosch

The highly miniaturized components are the glue that holds todays’ technological world together. The most powerful semiconductors are the core of all electronic systems and the various application fields include also the electric vehicles’, so that the company aids manufacturers in operating with more efficiency. The core of pre-integrated system solutions by Bosch is the advanced drive module, ADM, which integrates the single systems of propulsion, steering and brakes in a single harmonized flexible module. Simplified interfaces and a coherent software architecture decrease the complexity and assure the optimized communication among components. This modular approach that combines hardware, software and services allows manufacturing companies to integrate the ADM according to their requirements. The rolling chassis prototype, created through the collaboration with Benteler, specialized in the production of chassis and bodyworks, proves the highest possible level of pre-integration and represents a development platform for electric battery vehicles. With its integrated safety and control technology, the new flexible smart charging cable works also without the in-cable control box with 230-V socket. Without the so-called “charging brick” Bosch cable weighs less than 3 kg. On average, it corresponds to a 40% weight reduction compared to conventional cables with control box.

A new cooling concept: here is the durable electric motor by Mahle

Concerning this, the latest development comes from the automotive supplier Mahle: the traction motor can run indefinitely with high performance. A new cooling concept makes this technological leap possible. The new electric motor is surpassingly clean, light, and efficient and can be assembled without the use of rare earths by customer request. The new development is suitable for passenger cars and commercial vehicles as well as construction machines and tractors. With the SCT E-motor, Mahle thus becomes a full-range provider in the field of electric drives and covers all needs from e-scooters to heavy-duty commercial vehicles as well as off-road and industrial applications. The new item will be presented for the first time at IAA Transportation in September 2022 in Hanover.
Martin Berger, Vice President Corporate Research and Advanced Engineering at Mahle said: «Building large electric motors that deliver short-term high performance is easy. What was still lacking on the market until now were durable yet compact drives to make electric vehicles unrestricted for everyday use. Our new SCT E-motor is the solution. On the drivetrain side, this clears the way for the replacement of the combustion engine in all vehicle classes. In 2021, MAHLE presented a groundbreaking wear-free and scalable traction motor for passenger cars that runs very efficiently over a wide rpm range».
The SCT E-motor, on the other hand, is designed in such a way that it is particularly efficient within a certain rpm range. Despite its very compact and light design, its continuous output is more than 90 percent of its peak output. Unique on the market, this groundbreaking high ratio means a technological leap and allows the use of electric vehicles of all kinds even under demanding conditions. A classic example is driving an electric truck over mountain passes or the multiple sprints of a battery electric passenger car. These scenarios are only insufficiently covered by the electric motors available on the market up to now.
In designing the product, MAHLE opted for what is known as a permanently excited motor, since this type enables a very compact design and no energy has to be transferred to the rotor as “excitation current”. This makes the motor efficient and wear-free. Neodymium magnets, currently the strongest permanent magnets that can be produced, are used to generate the magnetic field in the motor. However, to achieve greater independence from raw material prices and geopolitical developments, the SCT E- motor can also be designed without magnets for greater independence. Thanks to the unique contactless transformer developed by Mahle, the magnet-free variant would also be wear-free and run efficiently, while only requiring slightly more assembly space.

Electric Green Tourer, here is Experia

The new e-motorbike produced by Energica offers interesting ideas for both medium-range use and for its technical characteristics. It has been available for pre-order since June 1st 2022 and the pioneering motorbike in the segment of electric Tourers is called Experia.
The motor, which weighs 260 kg (then less than Naked Eva one), is synchronous with permanent magnets and a maximum power of 101 HP (75 kW), for a torque of 115 Nm. The speed declared by Energica is 180 Km/h.
The autonomy stated by Modena company corresponds to 420 Km in the urban cycle and 246 km in the combined cycle.
What about the battery? It has a maximum capacity of 22.5 kWh and in 40 minutes, in the “Fast” recharge modality, it shifts from 0 to 80% of the recharge. Moreover, it is possible to use other two recharge modalities: Level 2 (at 240V) and Level 1 (at 120V).

The green strategy by Aston Martin: the race towards electric

It is called Racing. Green the sustainability strategy that will involve the whole Aston Martin under the supervision of the apposite Committee for sustainability. Assets include the net zero emission within 2030 in manufacturing plants and by 2039 on the whole corporate provisioning chain.
The electrification programme is one of the pillars, too. The automotive company foresees in fact to deliver its first hybrid plug-in, the supercar with central motor Valhalla, at the beginning of 2024. The release of the first electric battery-powered vehicle signed by Aston Martin is forecast by 2025, and within 2026 all new product lines will be available with electrified powertrain. Aston Martin is planning to electrify completely within 2030 the whole primary portfolio of GT and SUV sports cars.
The use of innovative sustainable materials is rising in vehicles by Aston Martin, which is exploring for instance the use of the ecologic aluminium alloy – produced with 100% of renewable energies – and of vegan leather-free interiors available as option, to offer a broader choice to customers and to reduce the environmental impact.

Electric releases: Fiat 500 “La Prima by Bocelli”

After the great success of the New 500 “La Prima Launch Edition”, New 500 “La Prima by Bocelli” is at its debut. The new version, first city-car with level-2 assisted drive, has an autonomy of 320 km, certified by the WLTP homologation cycle, which rises up to 460 km if used in the city traffic. The electric motor is the most powerful in the entire range, able to unleash 117 HP and 220 Nm of torque.
The great clamour is due to the fact it is the first city car in the world equipped with “Virtual Venues” technology by JBL for excellent-level audio experience. The new high-end version of the Fiat icon offers the JBL Premium Audio mastered by Andrea Bocelli as standard, an audio premium plant featuring 320 W of total power, highly refined in architecture and performances. To make the JBL audio system tailor-made for the vehicle, FIAT has availed itself of the experience of the most popular living tenor in the world, Maestro Andrea Bocelli.
“The amazing success of New 500 La Prima, the high-end model of our electric icon, has made us understand that our customers want a premium product, which is very Italian and very iconic: in other words, they pursue and they want the best of the Made in Italy – he states -. Precisely in Italy, we can find the utmost expression of art, of beauty and of music. For this reason,
Olivier Francois, CEO FIAT and Global CMO of Stellantis declared: «Together with maestro Andrea Bocelli, we have created the perfect listening experience to enhance the silence of a car. Besides, due to JBL technology, enriched by the excellent Virtual Venues system, we assure an immersive perfectly tailored listening experience».

The electric car of 2022-year? The new Volkswagen ID. Buzz

Top Gear Electric Awards celebrate the electrification importance in the automotive sector. Recently, on such occasion, the new Volkswagen ID. Buzz has been crowned electric car of the year, especially for the spacious interiors and the practical drive, praising it also for its iconic style, inspired by the original design of Volkswagen T1.
ID. Buzz is the first fully electric vehicle by Volkswagen Commercial Vehicles implemented on the Modular Electric Drive Kit (MEB) platform. Cian O’Brien, Director of Volkswagen Commercial Vehicles, affirmed: «As brand, we are living an important electrification travel, and the so longed-for ID. Buzz marks the beginning of this exciting experience. Being able to launch a car that is cool in design, with sustainability at the core of its creation, is an excellent way to show our customers it is still possible to do all things we like and travel wherever we want, even having a positive impact on the environment».
Moreover, here are the words by Ollie Marriage, Manager of Top Gear car tests: «People who pretend having an active lifestyle drive a SUV, those who actually do it drive a Volkswagen van. All those we have met have liked the brand’s rediscovery of its icon and have found ID. Buzz airy, fresh and energetic. Is it not phantastic that Volkswagen has finally had the courage of reinventing the original? It is charmingly simple and yet utterly uplifting. And, for this reason, it is our electric car of the year».

Harley Davidson: will LiveWire take off indeed?

It has been widely debated and it is a very controversial issue, which many Harley Davidson addicted do not like a lot. And if its first electric bike has not aroused a lively success in sales, it seems that the future holds another destiny. LiveWire, the electric “phalanx” of the famous American brand has in fact ambitious plans and states they are going to sell 100,000 units by 2026, which will become 190,000 by 2030.
Recently, HD has presented investors the financial prospect that reports how the market of electric bikes is in its early development phases but the forecasts of the global penetration of electric vehicles will expand from 6% of units in 2021 to 25% within 2030.
It would be a growth of the electric bike market worth $ 2.5 billion sales from about $ 20 billions to $ 28 billions in the same period”.
However, of what motor are we talking about? LiveWire is equipped with H-D Revelation, 105 HP (78 kW) electric permanent magnet motor, water cooled and featuring 116 Nm of instantaneous torque. Performances are equal to 0-100 in 3 seconds, resumption from 100 to 130 in 1.9 seconds and maximum speed of 177 km/h. It is powered by a 15.5 kWh lithium-ion battery encapsulated in a finned aluminium alloy casing to act also as heat dissipator and battery flanked by 12V for starting and remote control.

Here is the electric sports Lexus

Recently, Lexus has revealed a bit more about its next generation of electric battery sports car, showing various pictures. The new sports model will be part of a complete range of BEV that Lexus will release by 2030 under the vision of Lexus Electrified brand, through which the company aims at exploiting the electrification potential to increase the driving pleasure.
Lexus promises a unique driving experience based on the vehicle’s linear responses, consistently with the driver’s intentions, with the seamless connection of deceleration, of steering and of acceleration.
With its audacious proportions and the reduced height demanded for a high-performance sports car, the new model symbolizes the future of Lexus brand and revitalizes the spirit of the iconic Lexus LFA. The acceleration from 0-100 km/h in slightly more than two seconds and the autonomy will overcome 700 km, due to the possible use of solid-state batteries.

All-electric F-100 Eluminator concept

Good news for DIY enthusiasts who intend to drive an electric vehicle: Ford has released the EV Eluminator e-crate electric motor that costs 3,900 dollars and that might prove to be a key element in retrofit ambit. The motor debut occurred on a pickup F-100 dated1978: it was exported the original V8 motor featuring 302 cubic inches and the transmission to integrate two Ford Eluminator e-crate motors.
Based on a heritage 1978 F-100 pickup, the F-100 Eluminator concept features all-wheel drive via two powerful electric motors shared with the 2021 Mustang Mach-E GT Performance Edition.
Two electric traction motors drive the front and rear wheels, packing a powerful 480 horsepower and 634 lb.-ft. of torque. Eluminator, the first e-crate motor from Ford Performance Parts, is based on the Mustang Mach-E GT’s traction motor.
«Ford owners have personalized, customized and enhanced their vehicles since the beginning – from changing looks to bringing the power» – said Eric Cin, global director, Vehicle Personalization, Accessories and Licensing. – Our F-100 Eluminator concept is a preview of how we’re supporting customers as they go all-electric and embrace zero-tailpipe emissions performance, even for our heritage vehicles».
Ford has decided using two motors, each featuring 281 HP and 317 Nm of torque, providing the standard F-100 with a combined power of 480 horses and 634 Nm of torque and has chosen an 88 Kw battery system. The e-crate Eluminator still needs an inverter, battery cells, power supply controls and other to be fully operational, towards this direction Ford soon will add more parts and accessories for electric vehicles to Ford Performance catalogue, offering a broad range of options to customers.

Batteries: the new Audi research and test centre

Audi is expanding its development of high-voltage batteries and banking on the Neckarsulm location for that (l. to r.): Fred Schulze, Neckarsulm Plant Manager; Rolf Klotz, Chairman of the Works Council, AUDI AG plant, Neckarsulm; Oliver Hoffmann, Member of the Board for Technical Development of Audi AG; Stephan Reil, Head of Technical Development, Neckarsulm). (Please note: All persons pictured are in compliance with the 3G rule.)

Neckarsulm factory is at the core of the brand’s strategy that casts its spotlights on batteries and on the electrification process. Next years, the German automotive company will offer various opportunities of advanced training to workers, developing a centre dedicated to batteries to test high-voltage storage technologies. In the laboratory for pilot projects, the workers with more expertise will test the prototypes of new high-voltage storage modules for various electric vehicles. The new multifunctional building for the technical development unit will be accomplished by the end of 2022 and the structure is expected to start operating within 2023.
The decision of locating the development of batteries at Neckarsulm – explained Rolf Klotz, president of the works council – is a first important step to provide the technical development staff in that site with a safe prospect about the future, even after combustion engines will be stopped.
In Neckarsulm site, Audi is already creating the accumulators for plug-in hybrid cars and therefore it is already equipped for the electrification process that will lead the new models to be only electric starting from 2026.
«High-voltage batteries and electric motors constitute an important strategic component of the future value creation in a transformed automotive industry. For this reason, we are systematically enlarging our competence in the development of these important components» – stated Oliver Hoffmann, from Audi technical development.