One of the options Starlink customers have been waiting on, for quite a while, is the ability to use Starlink terminals while in motion. With Starlink Maritime the company released the ability to use the high-speed internet while in motion out at sea, but at last, there is an official option for customers who want to mount a Starlink terminal on top of their RV or other vehicles for in-motion use.
A team of researchers from UC Irvine and four national laboratories has fabricated a cobalt-free cathode for lithium-ion batteries.
The researchers relied on doping using HE-LMNO and magnesium, titanium, manganese, molybdenum and niobium inside the structure to fabricate a high-nickel cathode.
“Through a technique we refer to as ‘high-entropy doping,’ we were able to successfully fabricate a cobalt-free layered cathode with extremely high heat tolerance and stability over repeated charge and discharge cycles,” said research team member Huolin Xin. “This achievement resolves long-standing safety and stability concerns around high-nickel battery materials, paving the way for broad-based commercial applications.”
Working with researchers at four US national laboratories, Huolin Xin, UCI professor of physics & astronomy, has found a way to fabricate lithium-ion batteries without using cobalt, a rare, costly mineral extracted under inhumane conditions in Central Africa. Steve Zylius / UCI
“The highly stable structure is capable of withstanding more than 1,000 cycles and high temperatures, which makes it comparable to cathodes with much lower nickel content,” says UCI News.
In an article published in Nature, the researchers write: “Combining X-ray diffraction, transmission electron microscopy and nanotomography, we find that the cathode exhibits nearly zero volumetric change over a wide electrochemical window, resulting in greatly reduced lattice defects and local strain-induced cracks.”
“The combination of the different methods at NSLS II [National Synchrotron Light Source II] beamlines enabled the discovery of a trapping effect of oxygen vacancies and defects inside the material, which effectively prevents the crack formation in the HE-LMNO secondary particle, making this structure extremely stable during cycling,” says research team member Mingyuan Ge.
The publication notes that while the R1T made a great first impression, several problems have marred the experience since.
Source: Electric Vehicle News
Following XPeng’s recent 1024 Tech Day event in China earlier this week, we have finally been able to share video footage of its latest generation of eVTOL built by AeroHT. As promised during the presentation, XPeng’s flying car prototype completed its maiden flight and has the receipts to prove it. You’ve gotta see this.
Interplex has expanded its portfolio of interconnect solutions for EV batteries. The company’s Cell-PLX interconnect solutions are suitable for battery modules based on cylindrical and standard prismatic cells, and now it has released a new version that’s specifically optimized for next-generation prismatic cells.
Compliant with USCAR 2-6 automotive performance requirements, the Cell-PLX interconnect platform provides the data transfer capabilities needed for constant monitoring of voltage and temperature parameters, and supports battery module voltages from 12 V to over 800 V. Interplex says it can be adapted to suit any battery shape or size, including battery modules consisting of thousands of cells.
The company says its new Cell-PLX offering supports not only conventional prismatic cells in plastic carriers, but also the higher-density laminated-type prismatic cells that EV OEMs are now starting to specify for their batteries.
The new interconnect solutions can handle current densities up to 15 A/mm². They can be supplied with a choice of either aluminum or copper current-collecting layers, each accompanied by a UL 94-rated dielectric insulation layer. Plastic or metal housing options are available.
Cell-PLX is part of an expansive lineup of EV battery components (which also includes battery module enclosures, cooling plates, busbars and more). Interplex says its comprehensive vertical integration—stamping and molding, assembly (including laser and ultrasonic welding) and testing are all done in-house—enables it to offers its customers truly differentiated products.
“Incorporating laminated-type prismatic cells into EV batteries will mean larger amounts of energy can be stored within a more compact space. This is clearly advantageous, leading to battery modules that have tighter dimensions and are more lightweight,” Randy Tan, Product Portfolio Director for Energy, Interconnects at Interplex, explains. “Having an interconnect technology that is purposely aligned with these cells is vital. This should provide superior signal integrity alongside sufficient insulation. Now, with the newly-released Cell-PLX interconnect systems, we are well positioned to serve automotive OEMs looking to utilize laminated-type prismatic cells in their batteries.”
Mercedes-Benz is changing. For the German luxury brand that popularized the four-stroke combustion engine, the shift to electrification and carbon neutrality is about much more than propulsion. Like every other established and startup automaker, the industry faces an unprecedented crossroads where digitization, electrification, energy, and…
Source: Hybrid and Electric Car News and Reviews
Electric moped-maker NIU has spent the last few years expanding into a wider range of two-wheeled electric vehicles, including new e-bike and e-scooter models. Now the company is finally launching its highly anticipated BQi-C3 Pro electric bicycle.
The electric vehicle (EV) revolution gains more momentum every day, driving change to automotive manufacturing in unprecedented ways. With rapidly growing demand comes the need to rapidly scale assembly operations — and that can create significant challenges.
Vehicle manufacturers constantly seek new, more productive automation technologies to boost their quality and productivity. Along with many common assembly workflows, they face new challenges associated with scaling up battery pack and e-axle production. They need automation solutions to help integrate electric battery and powertrain production seamlessly into overall assembly processes.
Bosch Rexroth has an industry-leading portfolio of automation technology to satisfy these needs, with decades of experience providing manufacturing and automation solutions to leading automotive OEMs, as well as Tier 1 and Tier 2 suppliers.
Broad range of assembly challenges
Electric vehicles have replaced engines, gas tanks and transmissions with electric motors, regenerative braking technology and advanced battery packs. Assembling these new components presents unique challenges; at the same time, there are assembly processes common to both EV and internal combustion (IC) vehicle assembly lines.
For example, EVs have body parts that are welded using high-speed six-axis robots with advanced welding controls. Extremely precise control of weld quality is critical to the long-term performance of the vehicle; poor welds can lead to separation and vibration in body parts over time.
To solve these complex welding challenges with maximum speed and absolute quality control, Bosch Rexroth has introduced the PRC7000 welding controller platform.
The PRC7000 expands the number of heat blocks available, so plant operations can customize welding to specific throughput and material characteristics — a major advantage over older-generation systems. Also, it can store up to 10,000 welding programs that can be easily built via a drag-and-drop interface to incorporate more sophisticated welding sequences.
Improving manual assembly
Even though EV plants are highly automated, they also use the latest manual assembly methods to install a wide range of components and systems. Assemblers install headlights, windshields, retractable sunroofs, seats and door and window controls, often also connecting them to the vehicle’s control module. Exact precision in this process is critical to deliver vehicles that operate as flawlessly as possible.
Bosch Rexroth offers an advanced portfolio of intelligent tightening tools to provide the productivity and quality control needed for these manual processes. They provide the precise, repeatable performance crucial to high-volume assembly lines. The portfolio includes the EXACT ION series of cordless screwdrivers, offering industry-leading accuracy, durability and energy efficiency, as well as ergonomic design and lower weight to enhance worker comfort.
Wider use of these kinds of i4.0-ready tools helps assembly lines increase throughput and operate with greater flexibility as different vehicle models move through the line, while at the same time generating critical data that plant operators can use to improve training, adjust workflows and apply lean manufacturing principles.
Multiple technologies to boost battery pack production
There are four major steps in battery pack production common to most operations: electrode production, cell assembly, module assembly and pack construction, which also typically includes end-of-line battery testing.
Each stage uses a complex array of automation technologies to go from raw materials to completed packs. Given the critical role of the battery in the long-term performance and value of EVs, battery production requires high throughput rates combined with extremely tight assembly tolerances and quality control systems.
In electrode production, raw materials move through multiple automated processing steps. Maximizing control over these processes requires technologies that ensure cells are created with desired electrochemical properties, lifecycle and energy density.
Bosch Rexroth’s ctrlX AUTOMATION platform features advanced controller and drive systems designed precisely for these high-throughput production processes. The ctrlX CORE controller provides advanced closed-loop sag and loop control to eliminate breakage and minimize waste. It also supports high-speed multi-axis synchronization for web speed and position alignment.
In cell production, individual batteries — cylindrical, pouch or other format — are combined into cells. Many manufacturers are working to optimize the stacking process in this step because streamlining stacking can improve the throughput of the entire line.
High-speed robotic handling systems, either delta robots or linear robots, are essential tools in this stacking process. The Smart Function Kit for Handling is a highly efficient linear robot option well-suited to this process step. It is truly plug-and-produce: modern online tools support quick and intuitive component selection and configuration, and the pre-installed software allows for easier commissioning, supporting faster production start and helping speed to market.
Modular movement and transport solutions
Going from raw materials to a tested and installed battery pack presents a major automation transport challenge. With each assembly step, weight and component size increases, so a range of material transport conveyors and other systems is necessary.
From transfer systems for rapidly moving products weighing a few grams to linear motor-driven systems that can precisely transport up to over 400 kg, state-of-the-art conveyors and linear motor transport systems maximize efficient use of factory floor space and enable smoothly flowing, intelligently connected production.
VarioFlow plus plastic chain conveyors are proven systems that rapidly move cell assemblies horizontally, vertically, around obstacles or integrated with other process flows. These also support workpiece pallets to convey cell components where positioning or higher stopping precision is needed.
Further down the line, Bosch Rexroth offers the linear motor-based Flexible Transport System (FTS). It supports pallet-based transport and allows for individual carrier control for more complex movement at faster throughput rates. Combined with our intralogistics autonomous mobile robots (AMRs), Bosch Rexroth is uniquely equipped to address virtually every battery production transport challenge.
Successful assembly lines design conveyor and material transport solutions early in the development process, not as a final step once all the production machines and cells have been defined. This helps ensure productive movement of products and materials through every process step and prevents building in non-value-added transport time. Bosch Rexroth has deep experience helping select and connect different transport systems so the right material flow is established — and can be easily modified as production requirements evolve.
Automation insight to improve EV assembly productivity
As EV manufacturers are under pressure to expand production, they run risks by simply throwing technology at their throughput challenges, rather than considering how well their technology and component choices work together. All this assembly technology should be engineered and harmonized to maximize throughput without sacrificing the quality of the end product.
Bosch Rexroth can leverage its industry-leading automation portfolio and deep automotive manufacturing expertise to help prevent this risk. We have productive partnerships with leading factory automation specialists. They work with our experienced automation technology experts, following a unique, concurrent engineering approach.
Using this approach, we partner to conduct system design, programming and component acquisition and integration in tight, overlapping time frames to deploy complete automation solutions more rapidly.
Our solutions encompass virtually every major step in EV manufacturing, with specialized expertise in EV battery pack production. Our concurrent engineering methodology succeeds because we back it, and all our complete automation solutions, with global engineering, service and technical support resources.
Metis Engineering has earned ISO certification of its Production Battery Safety Sensor, which designed to monitor the health of a lithium-ion battery pack and detect cell venting. The sensor was developed using ISO26262 processes, and has been tested to ISO Automotive Standards by Applus+ 3C Test, an independent testing house.
Manufacturing of the production version of the Battery Safety Sensor has begun in the UK to fill orders from OEMs and Tier 1 suppliers, which are using them in ASIL B applications.
“Our Battery Safety Sensor measures pressure change and volatile organic compounds (VOCs) for the detection of cell venting, which is an early stage of thermal runaway,” said Metis Engineering Managing Director Joe Holdsworth. “It also monitors humidity, dew point and air temperature parameters to ensure that the battery continues to operate in optimum conditions.”
The sensor is designed to pick up a range of environmental parameters to ensure that the battery continues to operate in optimum conditions, and has an optional accelerometer to record shock loads. This data can be used to crosscheck with other inputs, such as cell temperatures, to check for cell venting. The sensor relays the data over a configurable CAN interface to a control unit, such as the vehicle’s ECU, to alert the driver that cell venting has occurred. The sensor can also trigger a process to cut the circuit to the battery pack, allowing it to cool down and prevent thermal runaway.
Metis says its Battery Safety Sensor typically detects venting within seconds.
“Thankfully, EV battery fires are very rare, but when they do occur, they are usually catastrophic for the vehicle,” said Holdsworth. “As cells age, the chance of one in a pack of hundreds or thousands going bad increases significantly. The early detection of cell venting is vital to the safety of the vehicle’s passengers and everything in the immediate proximity. We hope that this sensor offers an affordable part of the solution.”
Mercedes-Benz is changing. For the German luxury brand that popularized the four-stroke combustion engine, the shift to electrification and carbon neutrality is about much more than propulsion. Like every other established and startup automaker, the industry faces an unprecedented crossroads where digitization, electrification, energy, and…
