Volkswagen is the partner chosen to support the Vatican City State in its transition towards the sustainable mobility: the manufacturer will deliver slightly less than 40 full electric vehicles of Volkswagen ID. family, which range from ID.31 to ID.4 and ID.5. Mobility is at the core of a specific programme called “Ecologic conversion 2030”, which aims at reducing the CO2 footprint of the State’s vehicle fleet. To reach this target, the existing vehicles must be gradually replaced by electric ones, to make the whole fleet neutral from the point of view of CO2 emissions by 2030.
Through Volkswagen Financial Services, the automotive brand will supply the Vatican City State with a fleet of cars from the beginning of 2024. In successive phases, a growing number of zero-emission vehicles will be delivered also by Volkswagen Group brands, until the complete replacement of the whole fleet by 2030.
“The fleet electrification is becoming more and more important on a global scale. In future perspective, offering the drive of our ID. also to Vatican’s employees is a great achievement and honour for Volkswagen and highlights the attractiveness of full electric ID. models” stated Imelda Labbé during the delivery of vehicles in Vatican.
Vatican chooses the electric mobility
Customized robotics for the assembly operations of electric motors
Among the many successful projects recently installed by SIR Robotics, company that stands out in industrial automation, we can mention those related to the assembly of electric motors for e-mobility, compressors and heating convectors, welding of components for logistics warehouses and components for solid-liquid separation systems.
Besides, the company’s activities include the assembly of the powertrain group components, electric motor assembly, gearmotor assembly, assembly of electromechanical cooling groups, assembly of components for the mechanical industry and assembly of components for the electromechanical industry. Through the in-house Mechanical and Electronic Engineering, the idea for the electric motor assembly system turns into design and becomes project, scheme, layout, code. Everything is only and exclusively studied for the specific customer, shaped according to its requirements, rationalized and engineered, starting from a white sheet.
Hexagon, virtual prototyping to speed up design
The strategic partnership between the Manufacturing Intelligence division of Hexagon and JSOL Corporation aims at speeding up the virtual prototyping process for the powertrain group of electric vehicles.
“As the move towards electrification accelerates, new challenges need to be addressed to improve vehicle performance characteristics, from the component to system level. For example, improvements to noise, vibration, and harshness (NVH) performance now require simulation solutions to provide answers at much higher frequency ranges. Our partnership with JSOL solidifies our commitment to serve our existing and new customers in this rapidly evolving market”, are the words by Mahesh Kailasam, general manager of design and engineering at Hexagon’s Manufacturing Intelligence division.
“The electrification acceleration in various sectors, like the one of aerospace transports and of automotive, needs the use of simulation technologies to foresee with precision factors such as noise and vibrations, efficiency, duration and thermal management. This solution should be able to capture multi-physical effects in terms of component, subsystem and system.
Another challenge it is possible to win through the simulation is the creation of very light, efficient and innovative electromagnetic thrusters. “Hexagon and JSOL supply engineers with digital platforms and virtual environments that facilitate the development of sophisticated technologies of electric propulsion”, companies add in a press release.
Renewal of CSA accreditation for MGM Motori Elettrici
MGM Motori Elettrici laboratory in Serravalle Pistoiese factory has recently obtained the renewal of the accreditation by CSA for both safety-related tests and concerning inverter duty motors and energy efficiency (CSA C390). Although the range of already certified motors, in over 25 years of collaboration with CSA, is very broad, it is often necessary to certify new products according to the customization demanded by customers, or to update certifications after upgrades introduced on existing products.
The approval of MGM Motori Elettrici laboratory allows certifying new motors in shorter times, helping our customers, with a competent technical support, to release on the market reliable products in conformity with the regulations in force.
In addition to the safety aspect, in USA and Canada some regulations regarding motors’ energy efficiency are in force. For the conformity with such regulations, our motors are labelled on the plate with the marking cCSAus “Energy Efficiency” and “Certification Compliance number” released by the US Department of Energy (the CC number released to MGM Motori Elettrici is CC 051A).
Artificial intelligence for the creation of electric motors
An engineer from DNCL Technologies publicly talks about this hot topic, presenting the last novelties by the Indian company. DNCL Technologies provides Embedded Product Design and development company, DNCL offers Engineering Product Design Services and Industrial Design, Custom Electronics Product Design, IoT product Development PCB Design, Software Design included firmware and software programming services and RTOS services. «We started using an Artificial intelligence design service, and we are thrilled about the potential impacts of AI’s fusion with electric motors. We know that electric motors are a crucial part of many industrial and commercial applications and their efficient operation is essential to maintaining productivity and reducing costs. By implementing anomaly detection, condition monitoring, and predictive maintenance strategies, businesses can ensure that their motors remain in optimal condition, reducing the risk of downtime and costly repairs and extending the lifespan of their equipment».
About anomaly detection, «AI is our motor whisperer, picking up on those subtle cues we may miss. Abnormal vibrations, temperature spikes, unusual power consumption—all signs of underlying problems that left unchecked, could lead to severe damage or motor failure. Condition Monitoring is the round-the-clock guardian, keeping a watchful eye on key performance indicators like temperature, vibration, and power consumption. Machine learning models can detect those slight shifts in motor behaviour, hinting at potential issues».
Predictive Maintenance takes condition monitoring up a notch. By using advanced analytics and machine learning algorithms, AI can predict when maintenance will be needed. Imagine sensors installed in the motor system, collecting data on parameters such as vibration, temperature, current, pressure, and magnetic fields. This data is then processed and analysed to identify anomalies or patterns that could flag potential issues. Finally, by comparing historical motor performance data with real-time sensor readings, predictive maintenance systems can detect anomalies and predict when critical components may fail.
British researchers develop a super-light electric motor 3D-printed
The researchers of the University of Sheffield, in collaboration with a team of the University of Wisconsin-Madison, have developed the prototype of a new lighter and more efficient electric motor printed in 3D, using affordable metal PBF 3D printing technology. It might be a development able to pave the way to future electric motors to increase their power using less material.
The prototype uses a higher-percentage silicon electrical steel that reduces energy losses and it consists of a stator, a circular-shaped object with prongs that wires can be wrapped around to create a magnetic field.
The biggest design difference between the prototype and traditional stators can be seen in the prongs themselves, as they feature an intricate design of thin geometric lines meant to reduce energy loss.
«When you have 30% lower mass, you would expect that your torque would also be lower, but that wasn’t the case. So, this shows that you know you’re actually going to net torque density improvement in this machine and if we can further improve this, (making a more efficient 3D printed electric motor) would be a game changer» said one of the researchers.
Il team added: «This project has shown the large potential that additive manufacturing has for electrical machines, with lightweight, efficient structures that have never before been possible using any other manufacturing technique. It was a pleasure to work with the team at Wempec to turn this idea into a reality».
The RPLab laboratory opens the doors
In the Engineering Department of Palermo University, RPLab – Rapid Prototyping Laboratory is the laboratory where they design and implement prototypes of electronic power converters, control, conditioning and interface boards for research ambits in automotive, industrial and net-connected fields. Its interior hosts forefront LPKF Laser & Electronics machines. Managers have recently published a video that shows how is created an interface screen for an electric drive control based on a multi-level inverter and a permanent magnet brushless motor.
A showcase that accompanies the proposal of visiting the laboratory, which opens its doors to all to show its excellence and which is at the service of the Rapid Prototyping Laboratory graduation course.
Fraunhofer IPA: towards the “repair of motors”
20In the e-bike market, one of the hottest problems is the failure of the electric motor. Nowadays, the replacement of the unit occurs in the vast majority of cases. In the light of this situation, the team from Fraunhofer IPA Institute, headed by the project manager Jan Koller, wondered whether it was possible to develop a more circular motor model, providing for the repair instead of the replacement. The first step consisted in the implementation of 3D models and in the creation of spare parts with 3D additive printing, testing the various types of materials and manufacturing over 120 components in 20 different materials. Motors were then reassembled and subjected to severe tests on bench and with real load. Results? The motors so overhauled have offered the same performances as newly-manufactured motors, and with the same guarantee. What is more difficult, economically speaking, is establishing the breakeven point in the motor reconditioning business.
The new innovative battery by Stellantis that combines an inverter and a charger
After four years of intense projects and severe simulations, a team of 25 specialists who include engineers and researchers of Cnrs, the French National Centre of Scientific Research, has revealed a battery system known as Ibis (Integrated System of Intelligent Batteries). Ibis is supported by the Future Investment Plan, managed by Ademe (the French agency for the environment and the energy management) and coordinated by Stellantis. The primary participants in the project include Saft (TotalEnergies Group), E2CAD and Sherpa Engineering, together with the research laboratories of Cnrs and Institut Lafayette.
The specificity of this innovation resides in its design: the battery combines an inverter and a charger, notably increasing the efficiency and the longevity of batteries for electric vehicles. Moreover, this new configuration decreases costs and at the same time frees inner space in the vehicle.
Ibis is not only a product, but a real project that started in summer 2022, a system that changes the way according to which conversion boards are positioned as close as possible to the elements of the lithium-ion battery: a strategic position that allows the battery to produce directly alternate current for the electric motor.
Ibis has the potential to reduce the weight and the manufacturing costs of electric vehicles and to widen the range of available functions. From the point of view of the stationary energy, Saft provides for offering turnkey plants that enable a more efficient energy use, decreasing the environmental impact. Ibis battery by Stellantis also offers a simplified maintenance and an enhancement of plants.
Digital twins and electric motors, studies and startups to innovate
A global research by Altair, American company specialized in computational science and in Artificial Intelligence (AI), involved over 2,000 professionals from 11 sectors in 10 Countries on the Digital Twin theme. Results describe the widespread use of the Digital Twin in numerous fields, with the automotive in the first place, to make cars more efficient and sustainable and to shorten the time to market of electric vehicles. The automotive industry is the second major user of the Digital Twin technology (76%), just preceded by manufacturers of heavy equipment. The primary highlights would reside in the energy saving and in the more efficient use of resources (time, work hours and raw materials), with fewer rejects and wastes. Digital Twin solutions decrease, for instance, the material waste, through simulations and tests carried out during the design process. In this way, the number of physical prototypes needed before the production start is reduced.
Concerning the electrification of motors, Andrea Benedetto, CEO of Altair, stated: «The issue is always optimization. The challenge is to succeed in designing vehicles that weigh less and motors with higher efficiencies for specific use missions. In this way, performances improve and consumptions decrease. In this ambit as well, the Digital Twin can make the difference since development costs. It allows a faster and more efficacious process, driven by optimization».
Concerning this, a recent Italian example is Newtwen, a Padua startup set up by a team of three young researchers and two professors of the local University who have developed a software platform that generates extremely accurate virtual replications of physical systems, able to integrate them inside systems themselves to improve the performances, the longevity and the reliability, without the need of adding new electronic hardware components. The declared target is revolutionizing the future of the mobility and of the sustainable energy by decreasing the environmental impact and the consumptions of electric