Tuesday, September 27, 2022

Electrification strategy. Do you know the best small electric car?

It is an Italian symbol, currently also sustainable and 100% electric. For the second consecutive year, in fact, Nuova 500 by Fiat has conquered the title of “best small electric car” at “What Car? Electric Car Awards 2022”, due to its performances, the interesting price and the iconic design.
At present the Nuova 500’s list of trophies counts 33 international prizes awarded by the public and by sector experts in nine Countries. A success confirmed by sale outcomes: in just two years, it has been chosen by over 100,000 customers worldwide; it is the best-selling electric vehicle in Italy and in Germany and ranks on the podium in France and in Europe. «Diamond tip of our electrification strategy, then, the new Nuova 500 will soon land in the United States, prosecuting its global course outside Europe, after crossing Middle East, Brazil and Japan», stated Oliver Francois, FIAT CEO and Stellantis Global CMO.

The production of BMW i7 is starting

The production of the new Series 7 BMW and of i7 inside Dingolfing factory has started. The investment to adapt the plant to the production of the new sedan, offered also with Plug-in and 100% electric powertrains, the company has invested 300 million Euros.
The transformation towards a “BMW iFACTORY” is in progress, with much automation and optimization of processes, and to have more flexibility the new Series 7 is assembled on the same line of BMW Series 5, of Series 8 and of the fully electric BMW iX.
The direction is traced: by the end of 2022, one BMW out of the four leaving Dingolfing is expected to be equipped with an electric motor.
The electric BMW i7 sedan will be proposed in the xDrive60 variant with double electric motor able to deliver on the whole 400 kW (544 HP) with 745 Nm of torque. Due to the 101.7 kWh battery, the autonomy according to the WLTP cycle reaches 625 km.

Electric motors and cybersecurity

Cyber security concept. Shield With Keyhole icon on digital data background. Illustrates cyber data security or information privacy idea. Blue abstract hi speed internet technology.

The rise of electronic components in cars subjects them to a higher hacker attack risk. Currently, the onboard electronics constitutes 35% of the car value, with the prospect of reaching 50% within next ten years. Consequently, digital attacks will be favoured by an ever-rising IT complexity, but with a lower risk perception. As a matter of fact, already today acts of IT piracy in the automotive field are neatly rising, but underestimated.
For this reason, HSB Munich Re has recently carried out an investigation that has surveyed that 37% of the American owners of an electric car are very worried about their cars’ net safety.
Given the acceleration to the shift to electric cars, protecting these vehicles’ IT safety is certainly fundamental. For this reason, the University of Georgia has published a guide concerning electric cars’ information safety.
While previously risks were connected with warranty frauds or mileage alteration, in recent years privacy damages have emerged, cyber blackmails and warfare.
If a hacker attack against one’s own vehicle takes place, some other problems will occur, such as speed and acceleration damaged, decrease of the vehicle’s efficiency, batteries fully discharged and data unreadability on the display.
All signals exerting a negative impact on the vehicle’s safety. A list of suggestions to limit car hacking risks? Monitoring the onboard diagnostics, installing only reliable hardware, performing code reviews, updating software safely and installing a monitoring system of the cyber security.

France, Stellantis carries on the electric transformation

Whatever action by Stellantis has an unbelievable mediatic effect and can determine real changes of paradigm. Well, during one of his recent visits to manufacturing plants at Trémery-Metz in France, the CEO Carlos Tavares highlighted how the transformations of plants demonstrate the progresses made by the company towards the achievement of electrification targets expressed in the Dare Forward 2030 plan.
Let us remind them: the 100% coverage of sale mix with battery electric vehicles for cars (BEV) in Europe and by 50% of the sale mix of BEV with cars and light commercial vehicles in the United States within 2030.
Since 2018, the company has invested 2 billion Euros in French manufacturing sites. Well, through the investments in two key joint ventures at Trémery-Metz, Stellantis has deployed a vertical integration strategy aimed at increasing the control of the global electrification value chain. It is Emotors, a 50% joint venture with Nidec Leroy-Somer Holding, which in the current year will start the production of a range of forefront electric motors at Trémery factory, in the past the biggest manufacturing plant of diesel engines in the world and now the first Stellantis structure that produces electric motors.
The other is e-Transmissions, a 50% joint venture with Punch Powertrain, funded with an investment worth 57 million Euros, until now it is focused on the production of the next generation of electrified dual clutch transmissions (eDCT) at Stellantis factory in Metz.
The plant, renowned for its competences in the production of transmissions, is expected to increase its yearly production up to reaching about 600,000 eDCT within 2024 for the hybrid portfolio of Stellantis.
The Emotors M3 will be the first electric motors in the range.M3 will supply an efficient and economically competitive electric traction system, designed to operate with 400 V voltage and supply a power of 115 kW, which will make its debut on a Stellantis BEV by the end of 2022.
The eDCT transmission is available with two electrification levels, 48 V and 320 V, and it can be used for hybrid and PHEV applications.

The asphalt that electric cars like

This is a piece of news that can inspire electric market players for the potential synergy with the induction recharge technology for electric cars Dynamic Wireless Power Transfer (Dwpt). It is a new recharge frontier currently implemented in the experimental circuit “Arena del Futuro” of about 1 km, along A35 Brebemi motorway.
This technology allows the recharge of electric vehicles while travelling on dedicated lanes, thanks to an innovative system of coils positioned under the asphalt that directly transfer the necessary energy to the vehicles in transit.
The installed Dwpt technology is powered by a megawatt of energy and relies on 5G network for vehicles’ communication with infrastructures. The energy is provided by direct current net and photovoltaic plants, it is transformed into alternate with a suitable frequency for the wireless and then transferred to “coils” positioned under the asphalt. The technology can be adapted to all vehicles equipped with a special “receiver” able to transfer the energy coming from the road infrastructure directly to the electric motor, extending the autonomy and protecting the vehicle battery’s charge.

The stop to thermal motors is postponed

Blurred zoom image of traffic jam in the city at night

The market of electric motors and related components is looking with extreme attention at the official decisions concerning the stop to thermal cars, sanctioned by EU for 2035. The latest news about that reports an Italian Government that is going to propose the postponement for the complete stop to thermal cars by 2040, decreasing carbon dioxide emissions by 90 % within 2035. It is a political decision taken in common agreement with the national companies in the supply chain, choice shared also by other States belonging to the European Union, such as Bulgaria, Portugal, Romania and the Czech Republic.
It is certain that this acceleration to a final date is causing a lot of turmoil in the specific market and in all induced activities, final consumers included.

Innovation in the recycle of electric motors

In an industry that is expected to be increasingly green, recycling is a crucial theme, also and especially for electric motors. And there are no doubts about possibility of processing electric motors since up to 98% of its overall weight can be recovered, transforming it into secondary raw material. Concerning this, among the outstanding companies ranks the Italian Panizzolo, in Padua province, which ensures high-performance and wear-resistant system. The Italian player in the recycling system has recently communicated to the market to know only too well the issues related to wear and strong stress that the components, welds and steelwork are subject to. This is why the hammers and armours of Panizzolo are made in special anti-wear castings specifically designed jointly with the University of Padua – for the processing of bulky waste. The sorting of the outfeed granule is just as important.
The company invites to discover the mega 1100 hammer mill with electric power of 355 kW and a production up to 22 tons/h.

A new type of electric magnet-free motor?

The German manufacturer MAHLE, with headquarters in Stuttgart, is currently developing a new type of electric magnet-free motor. Its central feature is the inductive, and then contactless, power transmission, which allows the motor to operate wear-free and to be particularly efficient at high speeds.
Concerning this, the efficiency exceeds 95% in almost all operational points, a level that previously was reached by Formula E race cars only. In this way, MAHLE has succeeded in matching the highlights of electric motors’ various concepts in a single product.
It is an easily scalable development, which can be used by small cars as well as by commercial vehicles.
Moreover, the new electric motor is characterized by a long service life in time, because the necessary transmission of electric currents between rotary and stationary parts inside the motor is contactless and then wear-free. This makes the motor maintenance-free and suitable for a broad range of applications.
Michael Frick, Chairman of the MAHLE Management Board (ad interim) and CFO said: «With our new electric motor, we’re living up to our responsibility as a sustainably operating company. Dispensing with magnets and therefore the use of rare earth elements offers great potential not only from a geopolitical perspective but also with regard to the responsible use of nature and resources».
Dr. Martin Berger, Vice President Corporate Research and Advanced Engineering at MAHLE added: «Our magnet-free motor can certainly be described as a breakthrough, because it provides several advantages that have not yet been combined in a product of this type,” says “As a result, we can offer our customers a product with outstanding efficiency at a comparatively low cost».

Bentley is recruiting 100 engineers for its electric race

Group of young people job seekers or applicants sitting on chairs in row with resumes and waiting in line for interview invitation in office of modern company. Office career seekers concept

Bentley Motors’ recruiting campaign is underway for 100 talented engineers in the ambit of its Beyond100 strategy: the brand will release a new electric model every year starting from 2025.
The new engineers will support the implementation of the ambitious Five-in-Five plan, redefining Bentley’s credentials as reference manufacturer in the sustainable luxury mobility.
Therefore, they are searching for engineering professionals trained in the electric ambit because Bentley aims at the complete electrification of its product range within eight years.
Besides the need of electric engineers, next offers will concern the research and development ambit, from UX/UI engineers inside concepts and design, to Design Managers in the development and validation of parts and entire vehicles, to framework engineers who work at the prompt vehicle production.
«Bentley is in the middle of the most significant transformation phase in the company’s long illustrious history. We are searching for real innovators, who can create the new future of automotive, support our product ambitions and shape our Beyond100 vision while we are focusing on the leadership inside the luxury sustainable mobility», stated Matthias Rabe, member of Bentley’s research and development board.
Although roles are located at Bentley’s Crewe headquarters, the company has introduced the hybrid work, a combination of activity inside brand-new forefront engineering offices and smart working.
It is not fortuitous that at the beginning of the current year Top Employers Institute has appointed Bentley as “Top Employer“, only automotive manufacturer headquartered in the United Kingdom for the eleventh consecutive year, underlining Bentley’s approach to wellbeing, to values, to ethics and to employees’ integrity, in addition to Bentley’s attention to sustainability, digitalization and diversity and inclusion.

MANUFACTURING CONGRESS 2022: digital solutions for the connected factory

The Manufacturing Congress 2022 – Digital solutions for the connected factory is an important opportunity for the whole industrial world, to be informed about the best existing on the market as support to digitalization. A unique chance indeed, also due to its particular place and time framework. The event will take place in Bologna (Italy) on Wednesday June 8th 2022 at Volvo Congress Center, former GAM, sideways the main entrance of BolognaFiere.


The congress will be held the day before the opening of MECSPE exhibition (June 9-11, 2022), trade fair dedicated to the innovative technologies for the manufacturing industry.
The Italian manufacturing industry is called to look ahead and to embrace digital technologies, to turn each plant into a real smart factory: 68% of manufacturing companies highlight that increasing resilience is one of the corporate priorities; 77% of manufacturing companies agree about the fact that the digital transformation in production is essential for the future success; and 84% of manufacturing companies intend to embrace digital transformation technologies. The time has come of introducing with determination the change in all companies, because it is impossible to disregard the enormous opportunities that the digital transformation can create. Mainly, the collection and the analysis of data directly from plants enable the most reliable forecasts, allow producing more efficiently and permit higher resilience and sustainability.

The focus of the Manufacturing Congress 2022

In the scenario described above, the Manufacturing Congress 2022 is framed: satisfying a market that asks responses in the shortest possible time, always researching technologies that can transform each plant into a real smart factory with optimized processes and high safety and reliability levels. 5G, digital platforms, Industrial IoT, Edge Computing, Digital Twin, Artificial Intelligence and Cybersecurity, enabling a data exchange in big volumes, enhance communication and enable the monitoring from remote of plants, thus improving efficiency and productivity. Experience proves that the acquisition of data and the automatic learning lead to fast error-free ameliorations in production. Manufacturing Congress 2022 represents the most interesting opportunity of the year to remain updated about the trends connected with the digital transformation in progress, to know the best technological solutions and for networking with sector top players. The event will focus on: organizing the factory for a lean adaptive production; automation and robotics for the connected factory; virtual modelling systems, augmented reality, digital twin; 5G, Big Data, IIoT, artificial intelligence and Data Science in production; connected digital innovation for the sustainable factory. The congress will propose five parallel sessions: Automotive and vehicle industry; Food and drink industry; Packaging; Manufacturing systems and machining; Start-ups for digitalization.

Excellent names in the academic world and applied research have joined the Technical Committee of the Congress and will share, with their speeches, in ensuring the content authoritativeness.
Antonio Bicchi
Founder and manager of Soft Robotics laboratory by the Italian Institute of Technology of Genoa.
Marco Belardi
Contract consultant for the Ministry for the Economic Development (MiSE) for Industrial Policies for the Industry 4.0 – Enterprise 4.0 – Transition 4.0 plan; contract consultant in quality as Expert for Digitalization by the European Commission; president of UNI/CT 519 Technical Committee – “Enabling technologies for Industry 4.0” by UNI – Italian Standards Body.
Antonino Bonanno
Professor of “Hydrostatic transmissions” and of “Safety and reliability of hydraulic components” by the Executive Master in Hydraulics. He works by the Institute of Advanced Technologies for Energy (ITAE) of CNR.
Lucia Chierchia
Managing Partner of GELLIFY, B2B Innovation Platform that invests in digital B2B start-ups and guides companies in the design and execution of technological and innovation governance roadmaps.
Claudio Giardini
Full Professor in SSD ING-IND/16 “Machining Technologies and Systems” by University of Bergamo.
Mario Guagliano
Full Professor by the Department of Mechanical Engineering by Milan Polytechnics.
Paolo C. Priarone
Associate Professor of the scientific-disciplinary sector “Machining technologies and Systems” by the Department of Managerial and Production Engineering of Turin Polytechnics.
Annalisa Pola
Full Professor of Metallurgy by University of Brescia.
Paolo Rocco
Full Professor of Automatics and Robotics by Milan Polytechnics. Currently, he is a member of the Board of Directors of the University.
Marco Sortino
Associate Professor of Machining Technologies and Systems by University of Udine and Professor of courses in Mechanical Technology and Advanced Manufacturing Systems.
Andrea Zanchettin
Associate Professor of Automated Controls by Milan Polytechnics.