WEG has opened the Santo Tirso Industrial Park in Porto, an important milestone in the electric motor company’s strategic European expansion. According to WEG’s explanation, the facility will also be home to one of the world’s most advanced test and R&D facilities, allowing WEG to remain at the forefront of technological advances in the industry.
The company added that the impact of the new industrial park will extend beyond Portugal, offering substantial benefits to industries throughout Europe. In addition, this facility will enable WEG to ensure faster delivery times due to the increased reliability of the supply chain, with tailor-made solutions to meet customers’ specific needs.
“The state-of-the-art Industrial Park, the powered by 100 percent renewable energy, covers more than 100,000 square meters, more than 45,000 of which are indoor. The facility is one of WEG’s largest plants outside Brazil, and is set to become an advanced manufacturing and innovation hub that will serve key markets in Europe, North Africa and the Middle East,” the company explains.
The new park includes the HV Solutions Center, which is dedicated to the production of both medium- and high-voltage motors, including those with shaft heights up to 1,400 millimeters, and related control centers.
“This new industrial park goes beyond just a manufacturing facility-it is a strategic asset that will greatly improve both efficiency and sustainability for industries across Europe. Bringing new technologies and high-quality manufacturing closer to our European customers means enabling them to react faster to market demands, strengthening their competitive advantage,” said Marek Lukaszczyk, marketing manager for Europe and the Middle East at WEG.
As for the employment plan, the hub will create 100 new jobs in Portugal. “We started our business with a team of 154 people working for WEG in Portugal. Today we are more than 750,” commented João Cardante, sales and marketing director of WEG Portugal.
If lithium and other materials are concentrated in a few territories, alternatives must be found to make storage systems more efficient and improve the supply chain to our advantage.
A critical role in the energy transition in different sectors is played by batteries, whose diffusion is also supported by decreasing costs and the increasing share of electricity generated from renewable sources that increasingly needs storage systems.
In terms of chemistry, today batteries that rely on the use of lithium make up the vast majority of batteries used, which also rely on the use of cobalt, nickel, manganese, and graphite. These are materials that pose a problem when it comes to supply because today the production and processing of these materials are geographically highly concentrated in very few places. In 2019, for example, China was responsible for about 60 percent of global cobalt and rare earth production. Currently, every stage of battery production, from mining the minerals to using chemicals to produce the final battery components, is geographically concentrated in areas outside Europe. By the way, Europe is investing large sums of money in building facilities for cell production, assembly and recycling of batteries to become a key production location. In this direction, the Fraunhofer Research Institute, together with eight other research institutes, has developed the digital twin concept for battery cell production.
With “lithium batteries” we indicate a series of different battery typologies that contain, besides lithium, variable quantities of critical minerals, depending on the cathode chemistry. (Source and Credits: IEA)
The alternatives to lithium
The dependence toward certain materials found only in certain territories drives innovation and paradigm shifts toward optimizing existing technologies and developing new battery solutions. In this area, another key theme is battery recycling and remanufacturing: the opportunities arising from the management of spent batteries are already beginning to incentivize traditional players in the value chain to extend their expertise to adjacent roles.
Toward the cathode focuses the interest of researchers, including those at Fraunhofer ISI, who study lithium-ion batteries along with nickel, manganese and cobalt. Research to replace or diminish these minerals has led to various solutions, including metal-ion, metal-sulfide, air-metal, and redox flow batteries. Sodium-ion batteries have also attracted considerable interest from manufacturers because they do not require critical and expensive minerals such as lithium, but could be produced on the same production lines as lithium batteries, with all the advantages. To date, however, their energy density barely reaches 2/3 of that of lithium batteries, making them unattractive to the automotive industry.
Geographical distribution of batteries’ global supply chain. China dominates in each phase (Source and Credits IEA)
Advantages and obstacles
While on a theoretical level air-metal batteries involve the use of a metal other than lithium, on a practical level they present a number of complications.Another chemical combination that has been paid attention to is lithium-sulfide due to its high energy density, but due to its too short lifespan it is not yet so concretely appealing to the market.
Solid-state batteries, an emerging technology to extend the duration of lithium-ion batteries
In addition, flow batteries could become an alternative to lithium-ion for stationary storage systems, using vanadium as the primary element, but an obstacle here is economic.
Solid-state batteries are lithium batteries where, however, solid or near-solid electrolytes are used instead of traditional liquid electrolytes, with the goal of increasing the energy density of the cells and their safety. To date, there are limitations in terms of pack-level integration because they are subject to higher battery pressures. However, researchers agree to support the development of these batteries, particularly for applications that require long-range driving, such as electric trucks, especially in markets where the establishment of widespread charging infrastructure or battery replacement might be difficult.
Mercedes-Benz opened the eCampus at the heart of its headquarters in Stuttgart-Untertürkheim, the competence centre for the development of cells and batteries for the future electric vehicles of the brand with the star. The aim is to develop innovative chemical compositions and optimised production processes for high-performance cells with “Mercedes-Benz DNA” and reduce battery costs by more than 30 percent in the coming years. The Mercedes-Benz eCampus covers the entire field of battery and cell technology. It ranges from the development and evaluation of new cell chemistries and industrial-scale cell production to the testing and certification of complete battery units. Mercedes-Benz is developing various forms of cell chemistry. Among other things, the company is working on lithium-ion cells with high-energy anodes based on silicon composites and innovative cobalt-free cathode chemistries, as well as on solid-state battery technology. The aim is to develop the best possible cells with “Mercedes-Benz DNA” for high energy density, fast-charging capability and performance and to build up expertise for their industrialisation. Specifically, the energy density can be increased to up to 900 Wh/l through the use of new technologies such as high-silicon anodes or solid electrolytes. The only way to scale up production effectively is through comprehensive knowledge of cell chemistry and design. Operations at the new competence centre for battery technologies in the heart of the Stuttgart-Untertürkheim plant will start in two stages. The approximately 10,000-square-metre factory for the industrial production of battery cells has started operations after a construction period of around two years. State-of-the-art production facilities in the “Industrial Cell Lab” make it possible to manufacture and test battery cells with different chemistries on an industrial scale. Several tens of thousands of cells can be produced here every year for the development of future battery generations.
Futura, the sustainable propulsion boat, also composed of solar panels and an electric motor, built by the University of Bologna’s UniBoAT project, won second place in the prestigious Prince Albert Award, third place in the Championship Race, and third place in the Endurance Race, also consolidating its position in second place in the ranking of Italian teams. «Despite the unforeseen events encountered, such as a 40 percent reduction in available energy compared to competitors in the Endurance Race, a broken propeller blade and a rudder anomaly, the team managed to demonstrate the validity and efficiency of the innovative solutions proposed. The team is already working to solve the technical problems encountered, determined to further improve the performance of Futura, a boat that still proved to be an innovative and high-performance technological platform» the University researchers said. Compared to the past, the team decided to focus on a more powerful engine, introducing the need to develop a 96V system (from 48V) from scratch, with all the associated issues in terms of development and integration of other components. The entire thruster was also designed and built by introducing several innovations over existing solutions, which also led to the filing of a first patent related to counter-rotating trailing propellers for outboard applications, versatility, efficiency and lightness of the system. This year’s UniBoAT Project is part of the larger GreenWave Most Project, funded by the National Center for Sustainable Mobility (MOST) to demonstrate the feasibility of low-impact technologies in all areas of mobility.
Schaeffler tests innovations in electromobility in all environments. In temperatures ranging from -40 °C to +150 °C or in salt fog.
Schaeffler specializes in testing entire systems as well as components of their own products within the Schaeffler Group. These tests are functional, life cycle tests as well as simulations of external environmental influences concentrated in individual test sequences, which are technically and technologically demanding and can perfectly test our innovations for hybrid and pure electric cars. In most cases, Schaeffler engineers are testing innovations and prototypes that will go into series production in a few years’ time. Some of them will also be part of autonomous vehicles.
Sequential tests are a block of up to a hundred different tests, including mechanical, electrical and environmental tests. The test facility is equipped with state-of-the-art technology, measurement systems and stations that meet the most stringent safety requirements.
Thanks to special climate chambers, Schaeffler can create a simulation of the real environment for the test sample as if it were in a real vehicle, including extreme situations. Schaeffler can control the ambient temperature, but also the temperature of the oil or coolant. Schaeffler engineers also use universal climate chambers in their tests, as well as salt chambers that are equipped with inputs to control the sample via additional measuring technology, or shock chambers to test samples during temperature shocks. In the shock chamber we can induce a thermal shock from +220 °C to -80 °C in 20 seconds.
A total bandwidth of electrification options
Only by electrifying the powertrain mechanism can future fuel consumption and emission targets be fully achieved. That’s why Schaeffler offers products covering the total bandwidth of electrification options – from 48-volt hybridization through plug-in hybrid technologies to all-electric vehicle drives.
The Prädifa Technology Division of Parker Hannifinhas introduced CliPHvent, a new generation of vent valves for EV battery housings. In the event of pressure differences between the interior of a housing and the environment, as well as when sudden overpressure occurs inside a housing, CliPHvent ensures controlled pressure compensation or fast venting. This is particularly important in case of a thermal event in the traction batteries of electric vehicles.
Protection against sudden pressure increase caused by overheating
A “thermal event” or “thermal runaway” describes the sudden and rapid heating of a single or several battery cells due to a defect such as mechanical damage, an electrical short circuit, or overload. Especially in the powerful batteries supplying the propulsion energy in electric vehicles, thermal runaway causes huge amounts of gas to form inside the housing which leads to an uncontrolled and rapid rise in pressure and may have serious consequences up to and including the complete destruction of the traction battery and even the whole vehicle. CliPHvent vent valves from Parker Prädifa have been specifically developed toprevent that. By enabling fast venting via the integrated seal, they protect the battery housing resulting in higher safety of the traction battery. In the case of thermal runaway in a single battery cell, a domino effect, i.e., the spreading to adjacent cells followed by rapid propagation across the entire traction battery and its complete destruction, can be prevented.
Compensation of minor pressure differences, protection against ambient influences, easy installation
Minor pressure differences between the interior of the housing and the environment due to air pressure or temperature changes are compensated via a membrane. In addition, Parker aspire® membranes are water- and oil-repellent. As a result, CliPHvent vent valves provide reliable protection against ingress of external liquids and dirt.
The special, compact design of CliPHvent vent valves enables easy snap installation without the use of tools, on the battery housing or inside a bore.
As part of a project to develop a high-frequency capable high voltage dual inverter with a pioneering dual-redundant braking system, Yasa received new grant of over £7M from the Advanced Propulsion Centre. This is part of the ultimate aim to enable significant weight and cost savings whilst increasing regenerative braking potential in battery electric vehicles (BEVs). This project addresses key market demands for ever increasing BEV performance and efficiency, whilst also creating a validated safety case, which does not currently exist. The project will enable the realization of next generation electric-vehicle motor technologies. These complimentary and innovative technologies will together enable a step change in vehicle design and significant performance. Yasa have partnered with semiconductor specialists Cambridge GaN Devices, and Horiba Mira, and over the next 2 years, Project Re-Gen perfectly embodies world-class UK-based innovation, anchoring production expertise in the UK with a strong immediate route to market and great future expansion opportunities, delivered by a strong consortium with significant growth potential. Founder and Cto, Dr Tim Woolmer said: “We are delighted once again to be recognized by APC for Yasa’s ongoing commitment to the development of Net-Zero automotive technology. This award will be fundamental to our work in expanding our core expertise to incorporate power electronics and safety systems, enabling new architectures for electric cars of the future. We are thrilled to be working alongside Horiba Mira and Cambridge GAN Devices to bring this exciting development to the market in the coming years”.
Automating electron-beam welding, partnership between Ford and Cambridge Vacuum Engineering Cambridge Vacuum Engineering (CVE), a UK supplier of laser and electron-beam welding systems, and Ford, today announced that they have won a £430,000 research grant from Ukri’s Driving the Electric Revolution Challenge, offered by Innovate UK. The aim is to explore the automation and expansion of electron beam welding for joining copper and aluminium components used to power electric motors for the automotive industry. As part of the EB-eDrive project, CVE and Ford are trying to reduce the time needed to produce hairpin stators, the electromagnetic system that is crucial for the smooth running of electric vehicle motors. Speeding up this process could help to increase the production of electric vehicles in the UK, supporting government targets. It would also help strengthen the country’s position in the research and development of advanced manufacturing technologies. Zooming in on technology, electron beam welding is significantly faster than traditional laser welding techniques. The technology is already making a big difference in other clean energy applications, significantly accelerating the rate at which wind turbines and nuclear reactors can be produced, while reducing the amount of energy used and the carbon footprint of the associated processes.
MTA, multinational that operates in the global automotive sector through the two Electric and Electronic divisions, has announced the establishment of a new Research & Development Centre in Turin, in Mirafiori area, automotive excellence pole. The new centre, already in operation, will employ at steady-state about 25 engineers dedicated to the development of electric and electronic components, with a particular focus on products such as OBC (On Board Charger) and DC/DC converters intended for hybrid and electric vehicles, automotive, truck and heavy-duty applications. The new centre will host also a laboratory with test benches and forefront equipment to allow the autonomous execution of tests on power electronics components developed here. “We intend, as it already happens with Milan Polytechnics, to establish a relationship of fruitful know-how exchange with Turin Polytechnics, an excellence for the whole automotive world. Therefore, the centre will allow us to support vehicle manufacturers even better, with an increasingly articulated and technologically advanced offer for new-mobility requirements”, stated Antonio Falchetti, Executive Director of MTA.
As part of the Moving Boundaries 2 campaign, Mowo Social Initiatives Foundation has set out to train 500 women across Karnataka, Madhya Pradesh, Telangana, Maharashtra, and Delhi in electric auto driving. This transformative initiative, which kicked off on March 8th, 2024 aims to empower women by providing them with skills and opportunities needed to thrive in the electric auto-rickshaw industry. The team comprises an 8-member all-women crew steering an array of electric vehicles –auto-rickshaw, bike, and cargo van, set to cover 3,333 km over 30 days. «Our inspiring team of 5 women auto-rickshaw drivers consists of Naseem, Bhavani, Prabha, Reena, and Saritha. These trailblazers are driving ETO Motors electric auto-rickshaws in a relay format, setting an example and inspiring countless others to join the movement towards electric vehicle livelihoods» explains Tamanna Chaudhary di Mowo. Partnering with ETO Motors, an electric three-wheeler company, Mowo is dedicated to providing comprehensive training and support to participants. The vehicle is the BDY T3 electric van.
