Tuesday, March 5, 2024

Electrification grows by Citroen

They have recently announced the extension of Citroen C5 Aircross range: the SUV by the French brand now is also available with the new Hybrid 136 motors, based on the Hybrid 48V technology and also on a 48V battery that is recharged during some driving phases and a new Ă«-DCS6 gearbox that includes a 21-kW electric motor.
The electric synchronous permanent magnet motor has a maximum torque of 55 Nm, a 48V belt-driven starter motor and a new 6-speed Ă«-DCS6 electrified gearbox with dual clutch and no torque interruption. T
he battery is 48-V lithium ions with an available capacity of 432 Wh. The car is also equipped with a voltage converter, through which part of the electricity produced by the 48-V electric motor is also transformed into 12 V to power the car equipment.
Citroen stated that Hybrid 136 issues 15% of CO2 less than the equivalent non-electrified petrol version.

Nissan X in 1: new approach for the development of electric motors

Production line of electric motor in Yokohama Plant

Recently, Nissan has presented X-in-1, the new approach to the development of electrified powertrains to make Nissan motors 100% electric and e-Power more competitive due to the sharing and modularity of their primary components. The main advantages? More manufacturing efficiency, possibility of using the same production line, lighter and less cumbersome motors and reduction of rare earths to 1% of the weight.
With X-in-1, within 2026 development and manufacturing costs will be decreased by 30% compared to 2019 and the cost of Nissan e-Power models will be equal to the cost of models with standard thermal motor. Besides, the adoption of solid-state batteries starting from 2028 – which will cost the half and will be charged in one third of the time versus current batteries – will grant a further cutting edge to Nissan.
Nissan has implemented a 100% electric powertrain prototype called 3-in-1, consisting of 3 components: motor, inverter and reducer, and a prototype of e-Power called 5-in-1, composed by 5 components: motor, inverter, reducer, generator and multiplier.
«Due to the expertise and the know-how gained in over one decade in the development and production of electrification technologies, we will go on offering innovative high-quality products to our customers, favouring the diffusion of the electric mobility and of e-Power models», stated Toshihiro Hirai, Senior Vice President, manager of the engineering development of electric powertrains and of EV.
With Ambition 2030, Nissan is going to release 27 new electrified models, including 19 new full-electric vehicles, by 2030.

Supercar Lamborghini: the four-wheel drive makes its debut in full electric mode

Lamborghini has released the first technical info concerning the new 12-cylinder supercar LB744 that will be soon unveiled integrally. The first super-sports hybrid plug-in V12 HPEV (High Performance Electrified Vehicle) will be then ready to make its debut in the year of the brand’s 60th anniversary. The car’s goal is defining a new paradigm in terms of performances, sport character and drive pleasure, also thanks to a new architecture and a powertrain exceeding 1000 HP, combining the power of a brand-new thermal motor with three electric motors and the first dual-clutch gearbox that makes its debut on a 12-cylinder Lamborghini.
Compared to the previous powertrain, V12 has been rotated by 180° and is no longer equipped with the transmission in the front part but instead downstream the engine block, connected with the only rear wheels. The physical transmission shaft is replaced by the lithium 3.8 kWh battery that powers the electrified front axis, rechargeable at 7 kW, taking around half an hour to fill up.
The overall weight is 193 Kg, which includes the integration of a new fundamental component in the vehicle’s hybrid architecture, the rear e-motor, which has a maximum power of 110 kW and maximum torque of 150 Nm.
Placed above the gearbox, the electric unit performs the tasks of starter and generator, besides supplying energy to the two front electric motors through the battery positioned under the tunnel, acting as boost in the full electric drive modality and allowing the zero-emission four-wheel drive, directly acting on the rear axle. The tasks vary depending on the drive modality inserted, through an uncoupling mechanism. For that reason, it is equipped with dedicated synchronizer, which allows the connection to the double-clutch gearbox. When it supports the action of the V12, the e-motor is in the position that is defined P3, with electric motor downstream the gearbox, whereas it shifts to P2 to recharge the battery when stationary or at low speeds and it acts also as starter motor.
Electric powertrains improve the power delivery at low revolutions and can also make the new LB744 a fully electric-traction car, reducing the overall CO2 emissions by 30% versus the Aventador Ultimae.

Manufacturing excellence for Marelli motors that equip Maserati GranTurismo Folgore

The first electric car by Maserati brand is equipped with the forefront 800-V motors by Marelli – all featuring 300 kW of power -, developed in the course of two years and manufactured at Modugno, in Puglia, in a futuristic factory. The motors, one assembled on the front axle and two on the rear one, deliver a maximum installed power of 1200 HP, with power density of 9.2 kW/kg and maximum torque of 1350 Nm. It is a performance that can drive Maserati GranTurismo Folgore to over 300 kilometres/hour.
Marelli motors are made so performing by the manufacturing process: the rotor of the electric motor is subjected to a cryogenic cooling phase, in a chamber with temperature under -200 centigrade degrees to grant the perfect insertion of the shaft into the rotor pack.
Another innovative feature of Puglia factory is the use of an exclusive double process, of which one phase in 3D, for the stator manufacturing. Moreover, they carry out 70 quality tests, of which 41 fully automated, executed on the primary features along the whole manufacturing process.
Hannes Prenn, President and Chief Executive Officer – Vehicle Electrification Division, stated: «We are really proud of giving our technological contribution to a vehicle that marks a memorable time in the history of such an iconic brand like Maserati. Our consolidated technical know-how in the field of electric motors, combined with unceasing attention to innovation and well-rooted manufacturing skills, have represented key factors that have allowed us to develop the best solutions to assure the extraordinary performances of this unique car».

Geely’s new city e-car is intriguing

30After Tesla, the Wuling Mini EV car is the best-selling electric car in the world in 2022.
A result that acts as a beacon for the market, which pays increasing attention to the proposal of small e-cars especially suiting urban environments.
In this scenario, was born the Geometry Panda Mini by the Chinese Geely multinational manufacturer.
The tender bear, symbol of the Chinese culture, is then the inspiration of this car, recently exhibited in a mall in Hangzhou. What are the main characteristics? The car is 3.07-metre long, 1.52 m width, 1.60 m high and has a wheelbase of just 2.02 m. The powertrain is composed by a single electric front motor featuring 41 HP, which allows an autonomy of about 150 km.
The price is very interesting: the price list indicates from 5,000 to 7,000 Euros.

Audi, electric under test at Morocco rally

Absolute first in the race for the evolution of the innovative electric protype with range extender. Audi RS Q e-tron E2 is in fact engaged in Morocco Rally, with all official Audi Sport crews, for which very challenging conditions are expected: high temperatures, dunes, rocky stretches and fast tracks on compact ground.
The car is equipped with three electric powertrains: two MGU (Motor Generator Unit), one close to each axle, perform traction, whereas a third unit acts as generator to share in the recharge of the high-voltage battery.

Arnau Niubó Bosch, project leader track operations explained «The programme provided for nine days of test, so that each crew could test the car for three days. The main targets were two: developing the car in view of Dakar and making drivers and navigators become acquainted with the novelties introduced by the E2 evolutionary step. The car lightening, in fact, opens new opportunities for the trim and suspension setting. We are going towards the correct direction, to the extent that the electric traction discharges power to the ground more smoothly than in the past».

The car seems to differ notably from the past: the overall lightening allows opting for a less hard calibration of shock absorbers, to full benefit of comfort.

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.