Ceer and Rimac partnership for high-performance electric drive systems

Let’s first frame the key players in the collaboration, that has as object Rimac’s supply of high-performance, fully integrated electric drive systems (EDS) for Ceer’s upcoming range of flagship electric vehicles.

Ceer, a joint venture between the Public Investment Fund (PIF) and Hon Hai Precision Industry Co. (Foxconn), is building high-end electric vehicles as the first OEM in Saudi Arabia and the Middle East, while Rimac Technology specializes in electrification technologies, including drive systems, electronics and battery systems. The object of it all is Rimac’s supply of high-performance, fully integrated electric drive systems (EDS) for Ceer’s upcoming range of flagship electric vehicles.

(Foxconn), has signed a partnership with Rimac Technology to supply high-performance, fully integrated electric drive systems (EDS) for its upcoming range of flagship electric vehicles. The partnership was made official during a signing ceremony held at Rimac in Croatia on October 17 , attended by Rimac Technology CEO Mate Rimac and CEER Motors CEO James DeLuca.
“We are pleased to be the first company and the first large-scale project in the GCC to partner with Rimac Technology to equip Ceer’s flagship vehicles with the most advanced high-performance electric propulsion systems and solutions,” said Ceer CEO James DeLuca. “Rimac’s global reputation and expertise in designing cutting-edge high-performance propulsion systems aligns perfectly with our strategic goals of partnering with global industry leaders as we fulfill our commitment to deliver world-class high-performance electric vehicles and revolutionize the automotive industry in Saudi Arabia.”
“The partnership with Ceer further solidifies Rimac Technology’s global electrification ambitions,” said Mate Rimac, founder of Rimac Group. “This year alone, we have announced several key partnerships, including with BMW Group and Ceer, that will result in the production of tens of thousands of electric propulsion and battery systems for major OEMs around the world. With more exciting projects in the pipeline, we have strategically invested in our manufacturing facilities in Croatia, including the Rimac Campus and support infrastructure, which will soon be operating at full capacity.”

New Omron’s PCB relay requires up to 51% less mounting space

Lara Morandotti

Omron Electronic Components Europe has launched a new high power PCB relay, G6QG. It weighs just 18g e requires 488mm², so can contribute towards significant space savings while delivering high voltage and current endurance. In fact, the relay requires up to 51% less mounting space compared to similar 480VAC 55A relays.

For designers of energy infrastructure equipment PCB relay can contribute towards smaller and lighter boards and devices, or freeing up space for additional capacity or functionality.

“The relay is perfectly suited to high voltage energy infrastructure applications such as electric vehicles chargers and photovoltaic inverters”, explained Omron.

The company staied that despite its small size and low height, the G6QG is capable of high-capacity switching with a contact rating of 480 VAC, 55A. “The G6QG is capable of 10 kV high withstand voltage between coil and contact. Its coil holding voltage, which can be applied as 35%-50% of rated coil voltage, reduces coil power consumption to approximately 12% of rated voltage. Overall power consumption is 1400mW, is also saved as 172mW in case of coil holding voltage 35%”.

Repair and service is growing stronger for Schaeffler

Lara Morandotti

Recently, Schaeffler Vehicle Lifetime Solutions (VLS) has strengthened its core business regarding the repair and service of electrified vehicles. “The aftermarket will experience a sharp increase in demand for spare parts and repair solutions for these vehicles, making corresponding know-how and additional qualifications necessary.” The Schaeffler Group estimates that by 2030, 80 percent of all newly registered vehicles worldwide will be electrically powered, of which 40 percent will be pure electric vehicles and 40 percent will be hybrid vehicles.

That is why it has acquired Vitesco and will provide even more electrified powertrain products and solutions, including e-axle repairs. In fact, in 2022, Schaeffler Vehicle Lifetime Solutions introduced the E-Axle RepSystem-G as a transmission repair kit for the battery-powered Volkswagen e-Golf. Because the transmission and electric motor are contained in a single housing, the vehicle manufacturer offers only the entire electric axle as a replacement part, with no repair option. With the E-Axle RepSystem-G, however, this is possible.

The launch of Schaeffler’s second E-Axle RepSystem-G, a drivetrain repair solution for the Hyundai Ioniq, recently took place. As with the solution for the Volkswagen e-Golf, the manufacturer provides only a complete replacement in case of failure, but not a repair, as the repair kit with six bearings and seals allows.
In addition, the company is in the process of introducing an E-Axle RepSystem-M for the Ioniq, which allows for cost-effective replacement of electric motor bearings in case of failure. The kit contains two bearings, two flat seals, a rotary shaft seal, an O-ring, and sealing paste.

In addition, the Schaeffler division, together with GEDORE Automotive, has developed a special tool at the pre-production stage that allows contactless stator and rotor separation to prevent damage. Repair guides are already available for the two new solutions, and related technical training courses are being prepared.

Sitem celebrates 50 years of activity

Anna Bonanomi

This year Sitem S.p.a. celebrates the 50th anniversary of its foundation.

The company was founded in 1974 thanks to the entrepreneurial vision of Maria Landa Scarca who, together with her brothers and other local entrepreneurs, founded what is now one of the most important international companies in the field of magnetic laminations for high efficiency electric motors and generators.

«Together, we can continue to build the future of Sitem, always keeping alive the values and passion that have brought us so far, looking ahead with confidence and determination», said the CEO Marco Bortoloni

The party was held in a resort with a view of Assisi and was an evening full of emotions, where the important milestones that have marked the company’s history were retraced, and a special memory was given to Giovanni Bartoloni, who has contributed to the company’s growth over the last 30 years.

Innovation in steel for brake pad

Lara Morandotti

A supply of fossil fuel-free steel for use in brake pad shims, an important part used to eliminate brake noise, particularly in electric cars where annoying sounds are most clearly perceived. This is the subject of the agreement between SSAB, global steel company, and Trelleborg Sealing Solutions Kalmar AB, a manufacturer of sound-absorbing shims that wants to offer brake shims with a very low carbon footprint.

By changing the way steel is produced, SSAB wants to reduce emissions and create a fossil fuel-free value chain with customers and partners.
SSAB has developed two unique types of steel that are produced with virtually no fossil carbon dioxide emissions: SSAB Zero TM and SSAB Fossil-freeTM steel. SSAB Zero TM is based on recycled steel scrap and is produced with fossil fuel-free electricity and biogas and is available for commercial delivery from 2023. SSAB Fossil-freeTM steel is produced from iron ore using HYBRIT® technology developed by SSAB together with iron ore producer LKAB and energy company Vattenfall.

Stefan Lundström, Business Unit President, Trelleborg Sealing Solutions Kalmar AB

The technology, which has been tested on a pilot scale, uses hydrogen produced with fossil fuel-free electricity to produce iron, the primary raw material in steel production. The residual product is water instead of carbon dioxide.
“Our unique solutions to eliminate vibration and noise in cars are based on our technical knowledge and experience. With fossil fuel-free steel in our components, we will leap forward and strengthen our position as market leader,” says Stefan Lundström, Business Unit President, Trelleborg Sealing Solutions Kalmar AB.

“We are pleased to welcome Trelleborg Sealing Solutions as a fossil fuel-free partner. Together, we will support the automotive industry in delivering key components required by both manufacturers and consumers. In the end, we will deliver more sustainable cars to customers,” says Olavi Huhtala, head of SSAB Europe.

Anti-corrosion solutions

Lara Morandotti

For battery housings, an ideal solutions for automated and integrated ultrafine cleaning with corrosion protection are Plasmatreat’s Openair-Plasma and PlasmaPlus.

Surface treatment with atmospheric plasma technology is the environmentally friendly and efficient alternative to conventional cleaning methods for companies. In applications such as in the automotive industry, electric mobility or electronics, Plasmatreat GmbH’s Openair-Plasma and PlasmaPlus replace wet chemical processes such as electroplating. The innovative plasma technology can be used to finely clean the surfaces of various metals and alloys, such as aluminum, and apply wafer-thin coatings to prepare them for further processing.

For a battery housing enclosed by a lid, it is necessary to equip it with a reliable anti-corrosion layer

Anti-corrosion protection
When considering a battery housing enclosed by a lid, it is necessary to equip it with a reliable anti-corrosion layer. The requirements in this area are very high since batteries are often mounted on the floor of the vehicle. In this critical area, the battery is exposed to water spray, snow and road salt, which can be very aggressive to the battery. If moisture gets into the housing and cells, the functionality of the battery is compromised and, in the worst case, a fire can occur. That is why absolute sealing is a must. Liquid seals or, more recently, solid seals that allow the housing to be opened for repairs are used for this purpose. Plasma treatment promotes reliable sealing: after cleaning the sealing point with Openair-Plasma, the edge of the housing receives the PlasmaPlus AntiCorr coating for active corrosion protection. The AntiCorr coating, on the other hand, allows corrosion protection to be applied selectively, exactly where it is needed on the housing. The process is also much more environmentally friendly and, most importantly, dry, as it does not require chemical baths.

The AntiCorr coating allows corrosion protection to be applied selectively, exactly where it is needed on the housing.

For cleaning various metal alloys
Plasma technology is based on a simple physical principle: the addition of energy changes the states of matter. When energy is added to a gas, such as air, it ionizes and enters the high-energy plasma state, known as the fourth state of matter. When plasma, with its high energy level, comes into contact with materials, their surface properties change, such as from hydrophobic to hydrophilic. Plasmatreat has made this effect technically usable on a large scale with normal compressed air and under atmospheric pressure conditions. It does this with atmospheric plasma equipment, the so-called Openair-Plasma, and has developed innovative solutions for numerous material problems, which have proven particularly effective in the processing of various metals and aluminum alloys, for example. Depending on the type of contamination on the metal surface or application, outdoor plasma systems use different process gases, such as compressed air or formation gas.

In the PlasmaPlus coating process a functionalized surface with defined properties is created by nanocoating.

Protection without wet chemistry
Another process developed by Plasmatreat is used to treat metal substrates: the PlasmaPlus coating process. In this process, a functionalized surface with defined properties is created by nanocoating. A precursor is mixed with a carrier gas and forms a very thin layer on the surface. Plasmatreat uses various organic and inorganic groups for different precursors to treat metals and has developed highly effective PlasmaPlus coatings, including the PlasmaPlus AntiCorr process, which provides a high-performance anti-corrosion coating for housing gaskets and electronic components.

by Anne-Laureen Lauven

Critical inspection of electronic components

Lara Morandotti

OMRON-VT-X850-Inspection-Solution (1) — OMRON-VT-X850-Inspection-Solution

OMRON has launched VT-X850, a 3D computed tomography X-ray inspection (TC 3D AXI) solution designed to meet critical inspection needs in the electric vehicle (EV) and electronic component manufacturing sectors.

Innovative design and modern technology that ensures speed, accuracy and ease of use. These are the features of the new VT-X850 X-ray solution of OMRON, that integrates a high-voltage X-ray tube and artificial intelligence. In the spotlight is the inspection process of assembly modules, focusing mainly on filling connector cylinders and power devices, with an emphasis on detecting gaps or insufficient welds.

Key features
Among the pluses the company tells about the VT-X850 are higher speed and repeatability thanks to a high-voltage X-ray tube up to 160 kV, which ensures stable and clear images in a shorter time. In addition, the design accommodates modules up to 335 mm high and weighing up to 40 kg, ensuring wide applicability and versatility. Inspection is AI-based: binarization ensures superior image processing, making the VT-X850 an intuitive solution for users with different levels of technical expertise. In addition, the innovative design eliminates dependence on manual settings, offering precise and efficient inspections without the need for specialized skills.

Optimized user experience
VT-X850’s removable design ensures easy maintenance and replacement of the X-ray tube using a manual lifting device. The unit is specifically designed to meet the growing needs for inspection of hard and complex materials, particularly in the EV market.
“With the rapid growth of the EV market, the need for accurate, efficient and easy-to-use inspection solutions becomes paramount. VT-X850 is the ideal answer for manufacturers aiming for flawless quality control despite the complexities of different materials and components,” said Kevin Youngs, Sales Manager EMEA – Inspection Systems Division presso OMRON Europe

New steps for European semiconductor manufacturing

Lara Morandotti

Tobias Wölk, Product Manager Automation Technology & Active Components at reichelt elektronik, spoke about Europe’s key role in the production of the components of the future.

Let’s take a historical step back: the coronavirus crisis exposed the EU and U.S. dependence on Asian chipmakers. As demand for semiconductors exploded, production lines stopped, especially in the automotive industry. But today, chip production in Europe is to restart, and according to the European Chip Act, Europe’s share of semiconductor production is expected to increase to 20 percent by 2030.

*Tobias Wölk, Product Manager Automation & Active Components di Reichelt Elektronik*

The €43 billion European plan
“In terms of financial architecture, the European Chips Act will mobilize 43 billion euros in public and private investment, including 3.3 billion from the EU budget, and as of June 2023, funding has been approved for about 100 European projects,” saysTobias Wölk, Product Manager Automation Technology & Active Components, reichelt elektronik.
The manager stressed that Europe is only able to achieve true sovereignty in semiconductor manufacturing through a fully Europeanized value chain, from front-end to back-end manufacturing. “We need more manufacturing factories, but we also need regionalization of processing industries. Otherwise, we will continue to be vulnerable to disruptions in the global supply chain and our dependence on Asia will persist. A European semiconductor market can only be truly independent if all production steps are relocated to our Continent.”

Fragile supply chains
To save costs, many large semiconductor manufacturers have decided to outsource back-end manufacturing to service providers who specialize in the Asian market. These outsourced vendors are known as Outsourced Semiconductor Assembly and Test Vendors (OSATs) and perform this work on behalf of large semiconductor companies. Nine of the world’s ten largest OSAT suppliers are located in the Asia-Pacific region (six in Taiwan, three in China). The complex manufacturing process makes global semiconductor supply chains particularly fragile in the face of a product that, on the other hand, is critical and increasingly crucial. Therefore, the EU’s Chip Act plan to strengthen European semiconductor production is obvious.

Forecast
Simply relocating front-end production will not solve Europe’s dependence on semiconductors. “OSAT capacities must be increased to the same extent as front-end production. Otherwise, the localization of semiconductor production in Europe will remain incomplete and ineffective, as chips will still have to be sent abroad to be made ready for use,” Wölk explained.
There is also a lack of adequate manpower to achieve such ambitious goals. According to calculations by PwC Strategy, there could be a shortage of about 350,000 workers by 2030 to meet the EU’s ambitious 20 percent target.
“Another major bottleneck is the dependence on Chinese silicon production. Silicon, the most important raw material for microchips, is largely produced in China, a dependence that makes Europe vulnerable

Electric trucks, the crucial role of polishing

Lara Morandotti

The electric transition of heavy commercial vehicles, such as trucks, requires transmission technology made from gears with larger diameters, larger modules and finer roughness. Here is the challenge that gear and machine manufacturers are facing to meet the new market demands.

The transmission is subjected to different loads than in the past and must be made much more precisely. At the same time, transmission efficiency is a top priority by requiring low friction to minimize energy consumption and maximize vehicle range.

The new grinding machines
A whole series of Kapp Niles gear grinding machines are used at the Mercedes-Benz plant in Gaggenau for fine precision machining. For large gears, a new KNG 350 flex machine was purchased, which is suitable both for use in the prototype areas up to large series production. With the option of enlarging the work area and the use of combination grinding wheels up to 200 mm wide for superfinish grinding or polishing applications, large gears can be efficiently machined for e-mobility.

Kapp Niles KNG 350 flex gear grinding center

The KX 260 TWIN and KX 260 TWIN HS machines with small tools are used for gear shafts and enable continuous-generation grinding with dressable and non-grinding tools. The concept involves two identical workpiece spindles arranged opposite each other on a rotary table. Parallel to the machining of one workpiece, loading and unloading takes place, including the alignment of another workpiece on the second spindle.

Polishing superstar
When it comes to Polishing for commercial vehicles, increased side-loading capacity of gears and improved efficiency are essential. Kapp Niles machines use special worm wheels with two areas, one for conventional grinding and one for polishing grinding, making it possible to produce gears with roughness as low as Rz < 1 μm in a single take. “By now, polishing has been implemented across the entire line of electric gears,” the company explained.
The key challenge is to maintain stable roughness quality in mass production.

Combined polishing process of a large component for electric mobility

Large components
“When the design for the KNG 350 flex was developed, the focus was already on large components for truck transmissions, but at the time these were components with a diameter of about 300 mm. With the electric transmission, gears up to almost 400 mm in diameter have suddenly appeared. This affects both the work space and the handling area,” said Markus Reißenweber, sales manager Europe and America at Kapp Niles. With a weight of about 30 kg, the components have a heavier weight and a larger module that require new processes, such as polishing grinding and preparation for mass production, so they can run smoothly in three shifts.

(by Martin Witzsch)

Cylinders and suspensions: the choice of Ferrari Purosangue

Editorial Staff

TrueActive™ Spool Valve (TASV) technology by Multimatic comes into play by revolutionizing the role of shock absorbers, transforming a passive suspension into a completely active system.
Multimatic TASV shock absorber is pioneer to integrate a unique liquid cooled 48V three-phase brushless electric motor to deliver supplemental force through a bespoke twin-lead ball screw and gearbox assembly into the damper shaft and to the vehicle.
Each actuator group of the TASV shock absorber receives direct controls from a controller of the vehicle dynamics that constantly optimizes the vehicle’s performances and passengers’ drive comfort, far beyond what is possible with adaptive and semi-adaptive suspensions.
Alessandro Formenti, CEO at Vega Cylinders Company commented, complimenting on the choice of Ferrari Purosangue: “Imagine to drive your car without perceiving how you are moving. No longer feeling motor accelerations or pitching when cornering. It seems unbelievable, isn’t it? It seems a very distant choice from the sport driving. However it is the choice Ferrari made by installing some suspensions that annul drive sensations. These active suspensions have an electric 48V motor inside, connected with a special computer that reacts to the car’s stresses. Ferrari affirms this system helps fight load transfers and body movement, almost eliminating lateral body roll and shifting and distributing the load across the tyres. #Purosangue does not need anti-roll bars”.