My wife Becky and I received our AWD (2 engine) Cybertruck on March 29th, 2024, at the Seattle Tesla Service Center. The delivery experience was smooth and pleasant. I was excited to see how the Cybertruck compared to my 2016 Model S, which has 116,000 miles on it. On April … [continued]
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US-based GreenPower Motor, which manufactures and distributes medium- and heavy-duty EVs, has launched a new utility vehicle designed for commercial fleets.
GreenPower’s EV Star Utility Truck is purpose-built and fully customizable to fit a range of uses including agriculture and landscape, construction, heating and cooling, electrical and plumbing. The truck has a range of up to 150 miles and a typical payload capacity of up to 6,000 lbs. The vehicle is equipped with optional power sources, providing accessible power through built-in plugs to accommodate tool charging conveniently on a job site. The vehicle’s front box has optional full pass-through capacity, allowing for oversized tools and supplies.
“We have listened to our customers, and we are adding the EV Star Utility Truck to our EV Star Cab & Chassis product line to further diversify our all-electric commercial vehicle applications,” said Claus Tritt, GreenPower’s Vice President of Medium-Duty and Commercial Vehicle Sales. “Through GP Truck Body, customers can seamlessly order and tailor the EV Utility Truck with minimal time between order and delivery.”
Source: GreenPower Motor
Source: Electric Vehicles Magazine
As EVs continue increasing from a very small portion of the vehicles sold annually to a more mainstream presence on roads around the world, consumers and manufacturers are grappling with plenty of important questions. One set of these questions centers around a general “feeling” – that is, “How much does owning and operating an EV ‘feel’ like owning and operating the gas-powered vehicles I’ve used throughout my life?”
The future of EV development and infrastructure, in many ways, hinges on the perceived answers to this question. One natural comparison that people will make, for example, is what it’s like to “fill up” your vehicle at a station (either with gasoline or using a charger).
As designers continue to find ways to improve charging times (in a race to get EVs within shouting distance of the convenience of quickly stopping by a gas station), it is more important than ever for EV charging stations to maximize reliability and uptime. A recent survey found that up to a staggering quarter of public EV charging stations are not functioning, signaling a dire need within the EV industry for a reassessment of how to make EV charging stations as reliable and easy to use as their gasoline counterparts.
This massive gap between user experiences at EV charging stations and traditional gasoline/petroleum pumps is a fundamental problem facing the EV industry today. EV charging stations must maximize uptime and minimize downtime, and it is no exaggeration to say that the future of EV charging in America (and, surely, around the world) will depend on chargers that are constructed, from the ground up, with reliability and uptime in mind.
Power Innovations International (Pii) offers 30- and 60-kW Quick DC Chargers powered by components with an industry-leading mean time between failure, and these charging stations leverage a modular structure constructed for ensuring uptime with all-in-one cabinets that lower installation costs and simplify maintenance. These chargers bring unparalleled uptime for businesses looking to offer charging solutions for consumers at convenience stores, malls, offices, and hospitals, and to fleet managers looking to reliable EV fleet management solutions.
Pii’s Fundamentals of Reliability
The widespread adoption and implementation of electric vehicles depends on near-continuous uptime and highly reliable componentry. EV charging stations must capitalize on best practices for reliability to ensure that maintenance and upkeep are kept to a minimum, increasing ease-of-access and improving the overall user experience.
Reliability in individual components and systems more broadly are often measured in mean time between failure (MTBF), which is the expected time between failures of a regularly operating system. Consumer Affairs reports that there are just over 64,000 EV charging stations in the US, which means that there are over 56,000,000 potential operating hours every year for EV charging stations in the US.
Pii’s Quick Chargers feature integrated LITEON rectifiers that support the high voltage needs of a broad range of electric vehicles, with an output of 250 to 920Vdc. These rectifiers leverage the same power supply topology that has demonstrated over 1 million hours MTBF, and this demonstrated MTBF allows charging station owners and users the peace of mind that comes from proven reliability. A higher system MTBF increases uptime, reliability, and brings EV users closer to the experience they have come to expect with “filling up” a car.
Protection from the Environment and Avoiding Outside Air Cooling
A primary contributing factor to charging station failures and downtime is the impact of environmental factors, such as dust, liquids, corrosive chemicals, and much more. Stations must be able to withstand strong winds, rain, and snow, as well as drastic changes in temperature other regular meteorological events.
A failure to thoroughly account for these phenomena will lead to increased downtime and needs for repairs across an EV charging station’s life. Ingress protection and the sealing of the enclosure itself is not a “nice-to-have” in this industry: weather-resistant enclosures – with thermal management that allow for cooling without introducing outside, dirty air that requires filtering – will be a pillar of industry standards moving forward. In short, better shielding and protection for EV charging stations will be central to the industry’s goals of better reliability and near-continuous uptime.
NEMA enclosure standards include ratings for general-purpose enclosures that are not dust-tight (NEMA 1), enclosures that are drip-tight (NEMA 2), enclosures that are weather-resistant (NEMA 3R), and even those that are operable when ice-laden (NEMA 3S). Many manufacturers have opted to achieve the standard NEMA 3R certifications required for outdoor installations, while Pii’s DC Quick Chargers are NEMA 3S rated.
Pii’s ultra-reliable components are further protected by more stringent sealing standards that provide ingress protection of fine dust, in addition to the NEMA 3R requirements. Pii’s thermal management philosophy features air-to-air heat exchangers, meaning that they do not bring in outside air, simplifying maintenance and filter replacement requirements to further shield the internal components from the typical environmental degradation that comes with outside air filtration and cooling.
Modular Topology for Near-Continuous Uptime
Pii’s DC Quick Chargers use a modular internal power structure with sliding tray racks to help ensure uptime: the chargers are powered by multiple racks that independently supply power to the charging station, meaning that one individual rack’s failure will not cause a full system shutdown.
These power supplies are “field-swappable,” where a minimally trained technician can open a cabinet, visually identify the power supply issue, and replace it in a matter of seconds. In an industry plagued by long maintenance lead times and component shortages, Pii’s simple, modular charging station maximizes reliability and uptime across multiple dimensions: failures within the power conversion are demonstrably rare, but when they do occur, they will not cause cascading failures across the charging station.
Power Innovations International: Redefining Reliability for EV Charging
Power Innovations International has provided power management services to customers around the world since our founding in 1997. We are proud to unveil our line of EV charging products, accessories, and services, which comes out of close partnership with our parent company (LITEON Technology Corporation, one of the two largest global providers of power supplies).
As discussed in this article, Pii’s 30- and 60-kW Quick DC EV chargers were designed, first and foremost, with reliability and uptime in mind. These field-configurable chargers are easy to install and come with lower installation costs, providing the smooth, simple charging experience that EV adopters are increasingly – and rightly – demanding from the industry. These products are particularly suited for businesses looking to provide reliable, simple charging solutions at offices, hospitals, malls, or with dealerships or larger EV fleets.
This article focuses on one sliver of what makes these chargers the herald of the next generation of EV charging. Pii is vertically integrated in design and manufacturing for power conversion, as well as software/firmware controls, and final assembly.
Your EV charging plans don’t have to be held down by long lead times, expensive installations, and unreliable components: Pii is ready to help you reimagine what’s possible with your next EV charging station. Contact Pii today to learn more about how we can make your current reliability and uptime concerns a thing of the past.
Source: Electric Vehicles Magazine
BMW Group and Croatia-headquartered electrification technology developer Rimac Technology have announced a long-term partnership to co-develop and co-produce high-voltage battery technology for selected BEVs.
The two companies say their respective strengths will complement each other. BMW Group’s electrification strategy aims to build on its leading position and 15 years of battery and electric drive system expertise. Rimac Technology, as a Tier 1 supplier, offers a portfolio of in-house designed and produced high-voltage battery packs, e-axles, and electronics and software technology.
“The long-term partnership with the BMW Group is a sign of the Rimac Technology transition from niche high-performance solutions supplier to high-volume Tier 1 supplier,” BMW stated.
Source: BMW
Source: Electric Vehicles Magazine
US-based solid-state battery technology developer Factorial Energy has signed a memorandum of understanding with South Korean battery materials developer LG Chem to develop solid-state battery materials for EVs.
The agreement aims to combine LG Chem’s battery material capabilities with Factorial’s next-generation battery material and process innovations to accelerate the development of solid-state batteries. The two companies agreed that once the initial project is completed, they will discuss further technology licensing and material supply to maintain a strategic partnership.
In addition to its core business of cathode materials, LG Chem produces a variety of battery materials such as separators, conducting agents and binders and is expanding its R&D capabilities for new materials including solid-state electrolytes in response to changes in next-generation battery technology. The company has previously said that it aims to increase its annual battery material sales sixfold to $25.5 billion by 2030.
Factorial is developing its Factorial Electrolyte System Technology (FEST) for solid-state batteries to reduce EV weight, extend driving range, reduce charging time and improve safety. The company opened its battery manufacturing facility in the US in October 2023.
“The electric vehicle industry is at the cusp of a much-needed breakthrough in battery technology, and we believe that close supply chain partnerships will help accelerate this transition. Together with LG Chem, we’re advancing the development of critical solid-state battery technology that will unlock the electric vehicle future,” said Siyu Huang, CEO of Factorial.
Source: Factorial Energy
Source: Electric Vehicles Magazine
The Megawatt Charging System (MCS), a new charging standard for heavy-duty EVs that industry experts call a game-changer for electric trucks, is in the final stages of standardization, and is expected to enter the implementation phase this year. Automakers and EVSE manufacturers are busily putting the new system through its paces.
In the latest testing milestone, developers at Mercedes-Benz Trucks successfully charged a prototype of the eActros 600 at a charging station with an output of one megawatt (1,000 kilowatts) at the company’s development and testing center in Wörth am Rhein, Germany.
The engineers plan further trials of the communications interface between vehicle and charging station, defined as part of MCS standardization, as well as ongoing development of prototype components. The eActros 600 is planned to go into series production by the end of 2024. In addition to CCS charging at up to 400 kW, the eActros 600 will enable MCS charging at a full 1,000 kilowatts, once it becomes available, and the charging technology can be retrofitted.
The eActros 600 sports a battery capacity of more than 600 kWh, and a new efficient electric drive axle developed in-house. It boasts a range of 500 km, which will enable it to travel some 1,000 km per day with an intermediate charging stop during the legally prescribed driver breaks, even without megawatt charging.
Around 60 percent of long-distance journeys of Mercedes-Benz Trucks customers in Europe are shorter than 500 km.
Rainer Müller-Finkeldei, Head of Mercedes-Benz Trucks Product Engineering: “Our developers have put the newly defined MCS standard into the e-truck in the shortest of times with full charging capacity—an outstanding feat of engineering. Customers placing high demands on range and vehicle availability will benefit in particular from charging at 1,000 kilowatts.”
Peter Ziegler, Head of E-Charging Components, Mercedes-Benz Trucks: “The first successful megawatt charging test with our e-truck is an enormous step forward. We are now working at full speed to take the MCS technology in our eActros 600 to series maturity.”
Source: Daimler Truck
Source: Electric Vehicles Magazine
Norway-headquartered Vianode, a manufacturer of synthetic graphite for battery anodes, has released the results of a life cycle assessment (LCA) of its planned industrial-scale production.
A typical EV battery pack contains around 70 kg of graphite, which represents up to 40% of battery cell emissions, based on average present-day production. Vianode says the results represent a potential CO2 emission reduction of more than 90% compared to conventional fossil-based production, according to the latest LCA results, internal company analysis data, and specialist information provider Benchmark Mineral Intelligence.
The LCA is a scope 1, 2 and 3 study—from the point of resource extraction to the factory gate—of the prospective production of battery-grade synthetic anode graphite at Vianode’s planned large-scale site. Seven internationally accepted impact categories were considered: climate change, water scarcity footprint, land use, acidification potential, particulate matter, fossil resource use, and mineral and metal resource use. The study has been certified according to the ISO-14040 and ISO-14044 standards.
Vianode plans to open its first full-scale production plant at Herøya, Norway, in the second half of 2024 and scale up to produce high-performance anode graphite solutions for 3 million EVs annually by 2030 across Europe and North America.
“Vianode’s ambition is to change the way batteries and battery materials are produced,” said Vianode CEO Burkhard Straube. “In addition to leading sustainability metrics, our solutions offer high-performance properties that enable faster charging, longer service life and better recyclability of EVs.”
Source: Vianode
Source: Electric Vehicles Magazine
US-based ETCO, which manufactures electrical terminals and connectors, has launched a new line of heavy-duty locking ring terminals.
ETCO’s BT-Series Heavy-Duty Battery Terminals are designed for high-voltage wiring in EV batteries, alternators and starters in automotive, agriculture and construction equipment, process control and trucking applications.
The terminals are made from 0.06-inch thick brass or copper for maximum conductivity and are designed for ultrasonic welding. Featuring four teeth that extend 0.065 inches from the terminal surface of the ring, their sharp wedges bite into metal and anchor the terminal to help prevent unwanted rotation. Suited for attaching 0-6-guage wire by automated equipment, the terminals have an insulation support to bend around the wire jacket insulation.
Source: ETCO
Source: Electric Vehicles Magazine
Battery test engineers face a variety of challenges, including:
EA’s new EA-BT 20000 Triple Battery Tester was created to address these test roadblocks with a unique design—all in a more powerful test instrument. Read this application note to learn how one piece of equipment can test battery cells, modules, and packs with high-power density and cost-saving efficiency.
Source: Electric Vehicles Magazine
Contrary to the barrage of unsourced speculation on social media, EV adoption is indeed causing carbon emissions and oil demand to fall, albeit by a small amount so far. However, despite what many EV fans might assume, electric cars are not the main drivers of the reduction.
According to BloombergNEF, EVs as a whole displaced about 1.5 million barrels of oil per day globally in 2022—about 3% of total road fuel demand. Two thirds of that was due to electric bikes and mopeds. Electric passenger cars delivered a little over a sixth, and commercial EVs accounted for the rest.
In the US, bicycles and motorcycles are often considered recreational vehicles, but in other parts of the world they’re important parts of the transportation system. They are rapidly electrifying—according to BloombergNEF, EVs made up 49% of the global market for two- and three-wheeled vehicles in 2022, compared with a market share of 14% for passenger cars.
Bloomberg tells us that there were almost 300 million two- and three-wheeled EVs around the world in 2022, and that number has surely grown substantially since.
According to the International Energy Agency, over 95% of the electric two-wheelers are located in China.
Sources: BloombergNEF, International Energy Agency via The Guardian
Source: Electric Vehicles Magazine
