Thursday, March 28, 2024

Renault intends to halve electric vehicles’ manufacturing cost

Renault has announced the “Re-Industry“ plan, which aims at halving the industrial manufacturing cost of an electric vehicle by 2027. The goal, in the specific case, is assembling a Renault 5 in less than nine hours in Douai factory, in the North of France, decreasing vehicles’ development times from three to two years, accelerating the upgrade of Renault, Dacia and Alpine ranges.
To succeed in it, the steps are the creation of the Ampere electric branch, to digitize further and to develop its metaverse. Remaining in the technological innovation issue, the manufacturer expects to reach 3,000 operational applications of artificial intelligence in factories.
The automotive company intends to reach the neutrality of carbon emissions within 2025 in its ElectriCity plant in the north of France, expected to produce 500,000 electric vehicles yearly.

From Reliance gigafactory, the first tests on replaceable batteries

Reliance Industries, which is establishing in the Indian Gujarat State a gigafab of batteries where they focus on the cobalt-free and sodium-ions LFP technology, has started testing its replaceable EV batteries. These batteries can be recharged with the electric grid or with the solar energy and combined with inverters to power household appliances. However, it seems that the company is focusing on the electric mobility market and has created charge stations for interchangeable batteries in Bangalore. The users of electric vehicles can use a mobile application to find and to book the closest charge station, managed by Reliance, to exchange the worn-out battery with a fully charged one. Reliance New Energy has taken over the Dutch specialist of LFP Lithium Werks batteries, including the whole portfolio of patents, the manufacturing plant in China, the key commercial contracts and the engagement of the existing workers.
The use of LFP battery technology by Reliance is in compliance with the global shift towards cobalt-free cathodic chemistries, due to the availability and the price of cobalt in the production of metal-oxide batteries such as NMC and LCO.

Carpanelli, new line of electric motors with silver treatment

Patented by Carpanelli Motori Elettrici, GHA Carpanelli motors are a new line of electric motors with silver treatment, with remarkable antibacterial properties, ideal for the food and pharmaceutical sectors where maintaining a clean and aseptic environment is indispensable. They are ideated for aluminium-alloy motors and they represent a valid alternative to stainless steel electric motors, or to other expensive treatments where hygiene is priority. The G.H.A. (Golden Hard Anodizing) treatment is an innovative technology to be applied to aluminium alloys. The patented proceeding with anodic oxidizing enriched with silver ions provides the treated surface with exceptional anti-bacterial, anti-corrosive, anti-wear and thermal conductivity properties, moreover a protective layer of ceramic type, very hard, heat-refractory and unremovable is generated. The high conductivity of the silver-treated aluminium allows the motor to disperse heat with a 10-time higher contribution than stainless steel, therefore the casing remains colder. The fact of working at lower environmental temperatures assures a longer duration of components and an inferior condensate capacity. Moreover, the motor does not constitute a danger for the operators who might get in touch with it. The efficiency degree of the electric motor as well is favoured by the lower temperature. The antibacterial property of silver as well allows using these motors also in contact with foods, preventing and avoiding the bacterial proliferation and almost “sanitizing” foods themselves, interesting advantage for the companies that must comply with the international regulations for the hygienic product guarantee.

Electrification, Siboni has been taken over by Bondioli & Pavesi

Bondioli & Pavesi has accomplished the acquisition of 100% of the share capital of Siboni, company specialized in the development and manufacturing of electric motors and solutions for integrated electronics applications for customers in the industrial, agriculture, robotics and intralogistics sectors.
«Siboni family had been looking for a long time for a partner to go on growing, supported by the extraordinary work of those who, since when Enzo and Ivo Siboni had started in 1957, have collaborated and contributed in the company’s success», affirms Damian Molyneux, general manager of Siboni. «We have identified in Bondioli & Pavesi a partner with values aligned with ours, an innovative Group active in investments, people and technology and able to strengthen Siboni brand and to enhance its growth. It will be a challenging course to be accomplished together and, due to everybody’s competences, determination and commitment, will lead us to be more and more competitive». With the takeover of Siboni, the proposal in the electric and hybrid power transmission Bondioli & Pavesi-branded is integrated with the expertise and the applicative know-how gained by Romagna company in almost seventy years.
«We are excited with welcoming Siboni as new member of the family, certain that its technologies will provide Bondioli & Pavesi Group with a significant added value in the growth of the electrification for the agricultural and industrial sector», state B&P Owners. «With Siboni we share the passion for work, the care of people and the excellence pursuit, with the tireless desire of implementing innovative eco-friendly solutions, engineered in collaboration with customers».

ZF develops magnet-free compact electric motors

The German company ZF has recently presented I2SM, a magnet-free electric motor that, according to what stated by the company, assures the same performances as PSM motors. Everything, however, taking up less space and without using magnets, therefore without using rare earths. The credit goes to a particular design, where the energy transmission occurs via an inductive exciter inside the rotor shaft. A solution that not only avoids the use of magnets, but also the use of a large number of components seen on the first prototypes of magnet-free motors. The company has explained that, due to the use of the new ZF motor, the energy losses caused by the transmission might decrease by over 15%. Reduction by 50%, instead, for what concerns the carbon footprint that estimates the greenhouse gas emissions connected with the manufacturing of a product. The primary goal is making I2SM usable with both the current 400-V platforms and with the future 800-V platforms.

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.

GM will equip motors without rare earths

General Motors has recently announced the establishment of the partnership with Niron Magnetics, a United States company headquartered in Minneapolis that develops permanent-magnet motors with Clean Earth Magnet® technology , that is to say without rare earths, but with a technology based on the presence of iron nitride, an abundant and affordable material with great potential for commercial use in future EVs.
«We believe Niron’s unique technology can play a key role in reducing rare earth minerals from EV motors and help us further scale our North American-based supply chain for EVs,» said Anirvan Coomer, president of GM Ventures.«Our path to an all-electric future will be enabled not only by our own research and development efforts, but also by investing in next generation technology from startups and established companies outside our four walls».
GM and Niron have completed a strategic partnership agreement to co-develop Clean Earth Magnet motor technology that can be used in future GM EVs.«GM invented rare earth permanent magnets nearly 40 years ago, and now we’re working together to bring the next generation of automotive magnet technology to market,» said Jonathan Rowntree, CEO of Niron Magnetics.«We think that our Clean Earth Magnets can help GM in its goal to put everyone in an EV.»
New funding from GM Ventures, Stellantis Ventures, Shakopee Mdewakanton Sioux Community, University of Minnesota, and other investors will help accelerate commercialization of Niron’s Clean Earth Magnet® technology.

The new motor by Renault and Valeo without rare earths

Renault Group and Valeo have joined their competences to create a new generation of electric motors. Each of them has contributed with its own central piece (the rotor for Renault Group and the stator for Valeo) and their competence in technological development and manufacturing.
The new E7A electric motor will produce up to 200 kW: more power without the need of using more electric energy.
The volume-manufacturing of this motor will start at the end of 2027 in Cléon factory of Renault Group.
Their collaboration dates back more than one year ago and, according to the first details, the E7A motor by Renault and Valeo is 30% smaller – with the same power – in comparison with the present motors that equip the electric Megane E-Tech and the electric Scenic E-Tech.Besides, the carbon footprint is 30% lower.
Using a wound rotor instead of permanent magnets, Renault improves the motor efficiency, assures its provisioning chain and avoids depending on the Countries that produce rare earths and magnets. Moreover, the E7A motor without rare earths will also contribute in shortening batteries’ charge times, because the system will be at 800 Volts, besides the stator signed by Valeo will increase power and efficiency. In its high-end version, the range will in fact reach 20 kw (272 HP), without excessively weighing on autonomy.

Zero Emission Drivetrain for buses and coaches

zero emission drivetrain

Zero Emission Drivetrain (ZED) electric propulsion system, designed by Equipmake, now shines, in its latest upgrade, that includes electric motor, inverter and power electronics in-house developed.
Fully scalable and modular, Zero Emission Drivetrain (ZED) can be applied to any bus and coach.
It can be also implemented as retrofit of existing diesel vehicles, combined with the most recent ion-lithium batteries, the advanced technology of ZED assures high efficiency.
Its outstanding features include the ultra-efficient patented thermal management system, equipped with an advanced water-glycol cooling circuit, which keeps all components such as battery pack, motor and inverter at an optimal operational temperature, maximising the vehicle’s autonomy.
HTM 3500 electric motor is integrated into the shaft and it is designed to produce 3,500 Nm torque at a motor speed of just 1,000 rpm and supplying a maximum power of 400 kW.
Forefront lithium-ion battery packs are available in a range of sizes, from 327 kWh to 436 kWh and up to 545 kWh, offering maximum autonomies of 400 km.

Coatings for lighter components

The doubts about the autonomy, the weight, the cost and the use practicality of vehicles with electric motors lead to pay great attention to the development of more efficient, lighter and more compact batteries, electric motors and power electronics, which operate at higher voltages and allows the fast charge in DC.
“A clear target to be reached is these systems’ weight reduction and to achieve this result it is necessary to increase the efficiency of powertrain components and, in the case of the storage system, the density of stored energy. Concerning this, the new slot liner by Solvay, Ajedium™ PEEK allows satisfying the fundamental requisites in the design of electric motors but with the use of notably decreased thicknesses”, explained Stefano Montani, Marketing Manager Transportation at Solvay, Structural materials and Fuel Cell BOP.
This solution gives the possibility of notably increasing electric motors’ efficiency and consequently of reducing their weight, not only in terms of the component itself but of system as well.
“Until now, the materials used for the electric motors’ slot insulation have been mainly papers or paper laminates and films. One of the main drawbacks of this kind of solution is the strict hindrance on the thickness of the material itself. With the rise of the system voltage to 800 Volts and the adoption of the SiC technology for the power electronics, the resulting thickness with non-optimal materials is excessive, limiting the electric motor’s thermal and energy performances and, consequently, of the whole system, Stefano Montani added. Primary requisites are the following: maximizing the slot filling factor, minimizing the thermal resistance and allowing a better heat extraction from the system, supplying a suitable electric insulation and granting the electric motor’s expected service life. “In short, Ajedium™ PEEK has the potential of decreasing both the mass of the electric motor and the battery one. These systems’ mass reduction is enabled by the use of thinner PEEK slot coatings than thicker paper or laminate materials such as NKN”, the Manager of Solvay ended.