Leak Testing for Battery Systems in Electromobility: Challenges and Solutions Raphael Nold In recent years, electromobility has experienced remarkable growth, with the development of safe and reliable battery systems being of paramount importance. This article sheds light on the challenges and best practices for leak testing battery cells and housings in electric vehicles. Figure 1: Exploded view of a battery pack with its components that typically need to be tested for leak tightness. Fundamental Challenges in Testing: Battery Housings: Battery housings typically need to have a substantial v ..read more

EV Battery Design – Innovating for Longer Range and Battery Life Hwee Yng YEO The electric vehicle battery is one of the critical automotive technologies that have successfully scaled to support the e-mobility boom. The average EV battery pack cost $153 / kWh in 2022 – that’s a 90% price drop over a 15-year period. Looking forward, the automotive industry expects demand for Lithium-ion cells to grow by some 33% annually to 4,700 GWh by the end of this decade. More affordable EV batteries will help bring about the price parity between an EV and internal combustion engine car sooner than later ..read more

Revolutionizing Thermal Management in E-Mobility: High-Performance Sealing Solutions Monica Monte In the ever-evolving landscape of electronic mobility (e-mobility), pursuing higher efficiency, extended battery life, and enhanced safety remains paramount. One critical factor that significantly impacts these goals is thermal management. Efficiently dissipating heat generated by electronic components in electric vehicles (EVs) and other e-mobility applications ensures optimal performance and longevity. Schlegel Electronic Materials, a pioneering company at the forefront of sealing solutions, pri ..read more

Testing electromobility professionally Testing Hybrid and Electric Vehicles Klaus Leibold Electrical machines and drive systems place increasingly high demands on measurement and testing technology. Additional mobile and stationary test equipment is usually required in addition to conventional multimeters to ensure the safety of users. Functional and safety checks are absolutely essential, both on electric and hybrid vehicles and on the associated charging infrastructure. Ensuring this is one of the tasks that GOSSEN-METRAWATT has set itself. For years, the company has been working in close co ..read more

New materials and stacking technologies – Cost optimized Cobalt-Iron solutions for high performance electric motors Dr. Robert Brand High performance combined with small size and low weight are key requirements for electric drives. In applications with particularly high-performance demands such as aviation or motorsports, laminations made of cobalt-iron alloys are commonly used. Compared to classic electrical steel, this typically allows 20-30% higher power densities to be achieved. However, a technology transfer to roadgoing vehicles or high-performance industrial applications has rarely been ..read more

Next-generation testing for a safer today and tomorrow Advanced Driver Assistance Systems (ADAS) are standard equipment on electric vehicles, and serve to prevent accidents and make our roads safer. Testing the effectiveness of these systems requires engineering brainpower and robust methodologies to get it right. Product integrity and brand reputations depend on it. Aaron Mandalia The automotive industry is embracing a future that’s electric. The rapid development of Automated, Connected, Electrified and Shared (ACES) technology is changing the transport landscape forever. (Photoshoot 0322-02 ..read more

Martin Søgaard Electric vehicles (EVs) typically use regenerative braking, where the electric motor generates electricity that is stored in the battery. However, there are several brake conditions under which regenerative braking may not be an option (i.e., at low speeds, at speeds where deceleration is above a certain threshold value, and during emergency braking). Consequently, EVs are also equipped with traditional means of braking, typically disc brakes or drum brakes. As EVs carry a heavy battery, disc brakes are often chosen due to superior braking performance over drum brakes. Efforts t ..read more

New components for electromobility require novel manufacturing strategies According to expert estimates, by 2040 almost 45 percent of all passenger cars sold worldwide will have a battery or fuel cell drive system. This will result in a large number of new systems and components in production. This also poses a challenge to the supplier industry. Dr. Axel Luft Automobile manufacturers worldwide are working to reduce emissions. According to a 2022 study by the German industry association VDMA and FEV Consulting GmbH, almost 45 percent of a total of 128 million passenger cars sold worldwide will ..read more

Dr Sara Ridley The future of the electric vehicle (EV) industry is heavily dependent on the success of efforts to improve battery longevity and reliability. To become a truly sustainable alternative to internal combustion engine vehicles, EVs must also deliver on their environmental promise throughout the entire vehicle lifecycle While much of the focus around EV tends to be on battery recycling, EV battery repair technology will play a decisive role on this journey and represents a more environmentally friendly option. Recent advancements within this space have taken us closer to unlocking th ..read more

Charging batteries in record time A Swiss SME makes it possible to load an e-truck with freight and “refuel” its batteries in the same step. Patrick Kern As a start-up spun off from “Brugg Cables” three years ago, “BRUGG eConnect AG” now presents products that are making headlines in the sector. The SME’s strategy for success includes cable solutions for industry, wind energy and e-mobility. “With our charging systems, BRUGG eConnect AG, on the one hand, wants to make e-mobility accessible to everyone and, on the other hand, drive forward the energy transition,” says Patrick Kern, CEO of BRUGG ..read more