“This advanced variant of a separately excited synchronous motor is thus an alternative to permanent-magnet synchronous machines (PSM)” ZF explains in a recent press release. The novelty is a separately excited I 2 SM synchronous motor by ZF that transmits the energy for the magnetic field through an inductive exciter inside the rotor shaft. This makes the motor extraordinarily compact with the maximum power and torque density.
PSM machines are currently the most used motors in electric vehicles but they are based on magnets that need rare earth materials for their production. With I2SM, ZF establishes a new standard to make electric motors extremely sustainable in production and highly powerful and efficient in operation.
Dr. Holger Klein, CEO of ZF said: “With this magnet-free e-motor without rare earth materials, we have another innovation with which we are consistently improving our electric drive portfolio to create even more sustainable, efficient and resource-saving mobility. This is our guiding principle for all new products. And we currently see no competitor that masters this technology as well as ZF.”
Compared to common SESM systems, the inductive exciter can reduce losses for the energy transmission into the rotor by 15 percent. In addition, the CO2 footprint in production, which arises with PSM e-motors in particular due to magnets including rare earth materials, can be reduced by up to 50 percent.
An electric compact motor without magnets and rare earths
A technological kit for high peak power and absence of rare earths
The German manufacturer Mahle has recently presented an innovation in electrification ambit: a technological kit for electric motors that combines the advantages of its SCT and MCT electric motors. The MCT electric motor is the Magnet-free Contactless Transmitter and the electric resistance-champion SCT motor is the Superior Continuous Torque, which operates contactless and without rare earths.
The elimination of rare earths in MCT technology makes manufacturing more eco-friendly and implies also advantages in terms of costs and safety of raw materials. The MCT electric motor is characterized by long duration and the absence of maintenance because the necessary transmission of electric current among rotating and fixed parts inside the motor occurs contactless and then is wear-free.
The MCT electric motor features a high efficiency in a broad speed/torque range. The SCT electric motor is instead designed to reach the best efficiency in the main optimized operational points. Another highlight of the SCT electric motor is its high constant power. Despite the very compact and light structure, this corresponds to the 93-100% of the peak power, as the measuring results show. This unprecedented high ratio allows its use in electric vehicles of all kinds, even under very challenging conditions.
New smart mechatronic actuators for electric vehicles
In a scenario where we expect that the cars of the future will include more than 100 actuators with different functions, Marelli releases its new range of smart multifunction mechatronic actuators intended for electric vehicles, designed to simplify the actuation of complex functions.
The new actuators include an electronic module, which autonomously controls the actuator itself and connects it with the electronic net of the vehicle. The device features a flexible, modular and scalable mechanical design, able to suit complex configurations of the vehicle concerning electronics and transmission, and a software management designed to simplify the integration. Spotlights are then cast on the transmission of hybrid and full electric vehicles that find application in several systems
A new low-inductance 650kW continuous-power motor
X-Division SPX177 is the most powerful motor for BEV electric vehicles ever manufactured by the British company Helix, famous for its package that they define Scalable Core Technology (SCT). With a weight of just 28 kg and a constant power of 650 kW, this motor will equip a hypercar by a manufacturer not revealed, yet. «It’s small and weighs just 41kg, including the 13kg inverter. It is a 2x 3-phase motor, so its current is shared across two inverters, a necessary approach to meet the phase current demands at ‘normal’ DC voltages at this extremely high-power level. Both the motor and inverter have extremely high-power density. Six high-voltage cables connect the inverter to the motor, while an LV connector carries the various control signals», affirmed the project manager Derek Jordanou-Bailey, head engineer of Helix. He added that the motor uses the ‘top end’ of materials.
What potential of lithium metal solid-state batteries?
The results of recent studies carried out by an international research group that includes the University of Oxford and Nottingham and the University of Pisa show that lithium metal solid-state batteries (Li-SSBs) grant a high energy density and, in the future, they might be used in electric vehicles, making them even more sustainable from the environmental point of view, revolutionizing the electric mobility and freeing it from the dependence on materials like cobalt and nickel.
Li-SSBs are distinct from other batteries because they replace the flammable liquid electrolyte in conventional batteries with a solid electrolyte and use lithium metal as the anode (negative electrode). The use of the solid electrolyte improves the safety, and the use of lithium metal means more energy can be stored. The hindrance still present today concerns the scarce speed owing to the present catalysers.
«Progressing solid-state batteries with lithium metal anodes is one of the most important challenges facing the advancement of battery technologies. While lithium-ion batteries of today will continue to improve, research into solid-state batteries has the potential to be high-reward and a game-changer technology», said Dominic Melvin, a PhD student in the University of Oxford’s Department of Materials, one of the co-lead authors of the study.
The research pursues the creation of new classes of catalysers and the use of different materials versus the ones used until now.
Fiap presents new stainless-steel synchronous motors
Fiap Spa – Pneumax Group has released on the market two new modes of stainless-steel synchronous electric motors. “Dertec fo Fpm3ss series stand out for hygiene and efficiency and feature a new Signature Line design that combines the last technologies to achieve the best efficiency and the utmost possible hygiene. These electric motors can also be equipped with encoders for the speed and position control”, the company explained. Electric stainless steel synchronous Ac Dertec Signature Line motors series SL4PSS have been developed with the target of improving efficiency, on average higher by about 10%. The current IE3 standard is expected to become more severe in the next future and electric stainless-steel synchronous motors Dertec Signature Line already conform to the foreseen IE4/IE5 standards. Moreover, they offer a high Cos Phi on almost the whole power range. The synchronous operation makes these electric stainless steel motors ideal for the speed and position control.
BorgWarner and onsemi, strategies in inverters for higher performances
BorgWarner will integrate 1200 and 750 V power devices of EliteSiC series by onsemi in its own Viper power modules for traction inverters, specifically ideated to enhance electric vehicles’ performances. The collaboration between the two players was born just for silicon carbide devices (SiC): the signed agreement – the companies announce – will generate profits exceeding one billion Euros in the lapse of its own duration. onsemi supplies the products of high-performance EliteSiC range assuring the high standards, in terms of quality, reliability and supply continuity demanded by the market of traction for electric vehicles.
“onsemi’s strategy that provides for unceasing investments aimed at increasing the manufacturing capacity of SiC devices by exploiting its own end-to-end supply chain – underlined Stefan Demmerle, vice president of BorgWarner and President and General Manager of the PowerDrive Systems division – grants us the possibility of going on supporting the steeply rising demand for our solutions, both now and in the future”.
Silicon carbide traction inverters by BorgWarner already at present grant more efficiency, higher cooling performances and faster recharge speeds. Thanks to the use of EliteSic technology, the solutions by BorgWarner will be characterized by even higher power density and efficiency levels, with consequent increment of both the autonomy and the overall performances of electric vehicles.
“The integration of EliteSic technology into traction inverters allows increasing electric vehicles’ energy efficiency – affirmed Simon Keeton, Executive Vice President and General Manager of the Power Solutions Group of onsemi – contributing to mitigating the fuelling anxiety, one of the major hindrances to the adoption of electric vehicles.
Solaredge releases on the market bi-directional battery chargers for electric vehicles
The sale of the first models is expected by the second half of 2024.
The Israeli manufacturer of inverters and batteries SolarEdge has unveiled a bi-directional DC-coupled electric vehicle charger for electric motors. The DC-coupled architecture of the device allows the simultaneous charging of electric vehicles directly from photovoltaic systems, from residential batteries and from the grid.
The battery charger is connected with a single-phase or three-phase inverter by a DC bus circuit that can be oversized up to 200%, permitting to recharge the electric vehicle with the photovoltaic energy in excess. The battery charger has a charge/discharge speed of 12/24 kW and a DC to DC 99% peak efficiency. The sizes of the device are 620 mm x 340 mm x 200 mm, it weighs 22 kg and is provided with a 7-metre cable. It can operate at temperatures included between -30 C and 50 C is equipped with an envelope classified IP-65 for internal and external use.
V2G applications allow automatically charging and discharging electric vehicles’ battery according to the dynamic prices of utilities. This permits house owners to receive payments by their electricity provider by discharging the energy of electric vehicles’ battery stored in the net during events of response to the demand.
Moreover, users can use the electric vehicle’s battery to carry out the backup of their dwellings when the vehicle is parked by using a V2H application. The battery has a maximum capacity of 50 kWh.
“The battery charger will be compatible with both powertrains for electric vehicles featuring 400 V and 800 V through a CSS standard connector”, stated Solar Edge in a note.
Hypercar, from Helix a low-inductance 650kW continuous-power motor
X-Division SPX177 is the most powerful motor for BEV electric vehicles ever manufactured by the British company Helix, famous for its package that they define Scalable Core Technology (SCT). With a weight of just 28 kg and a constant power of 650 kW, this motor will equip a hypercar by a manufacturer not revealed, yet. «It’s small and weighs just 41kg, including the 13kg inverter. It is a 2x 3-phase motor, so its current is shared across two inverters, a necessary approach to meet the phase current demands at ‘normal’ DC voltages at this extremely high-power level. Both the motor and inverter have extremely high-power density. Six high-voltage cables connect the inverter to the motor, while an LV connector carries the various control signals», affirmed the project manager Derek Jordanou-Bailey, head engineer of Helix. He added that the motor uses the ‘top end’ of materials.
The Electric Wave solution to convert boats
Converting conventional boats with thermal engines into electric or hybrid ones is the goal of the Electric Wave startup, system integrator in Ancona for the electric boating, operating in the development of a port charge network with a circular nautical zero-emission approach.
The company has implemented a demo boat, EW01, full electric: an 8.5 metre long goiter, with a 15 kW Bellmarine motor provided with photovoltaic awning with Sunerg modules with bifacial cells and with a power of 1 kWp. The vessel is available for potential owners interested in the advantages of silence, comfort and sustainability, which implies that this electric boat travels at a speed of 5 knots. In a sunny day, the boat has an autonomy of over 6 hours in full electric modality, which can be extended to 20h by using the suitable Range Extender kit in hybrid modality.