Electric vehicle (EV) powertrains comprise the components that convert stored electrical energy into mechanical motion. These systems span the inverter, electric motor, single-speed gear reduction, and control electronics. Powertrains also integrate … [Read more...]
Understanding reconfigurable EV battery packs
Reconfigurable battery packs dynamically adjust internal connections, voltage, current distribution, and power output. Unlike conventional fixed packs, they isolate faulty cells, balance power loads, and respond to dynamic energy demands. These … [Read more...]
How high-power dc fast chargers manage heat and impact EV batteries
Fast electric vehicle (EV) charging standards, such as the Combined Charging System (CCS) and Charge de Move (CHAdeMO), regulate the safe, efficient delivery of direct current (dc) to battery traction packs. As shown in Figure 1, high-power dc … [Read more...]
How to rethink EV battery metrics for real-world performance
Most of the automotive industry still relies on standard metrics such as cycle life and energy density to evaluate electric vehicle (EV) battery performance. While useful for benchmarking in controlled settings, these metrics often fail to reflect … [Read more...]
How is temperature, voltage, current, and EMI managed in EVs?
Monitoring and controlling temperature, voltage, current, and electromagnetic interference (EMI) help ensure the efficiency and safety of key electric vehicle (EV) components. This article explores how embedded EV sensors accurately measure … [Read more...]
How e-fuses, circuit breakers, and isolators enhance EV safety
Electric vehicle (EV) manufacturers integrate e-fuses, circuit breakers, and isolators into key systems to protect against fluctuating high-voltage currents. These components activate within microseconds to prevent faults, failures, and thermal … [Read more...]
What role do thermal interface materials (TIMs) play in EV battery systems?
Automotive manufacturers rely on thermal interface materials (TIMs) to prevent overheating in electric vehicle (EV) batteries. TIMs improve thermal regulation across traction packs by optimizing heat transfer between key components and supporting … [Read more...]
How EV charger–battery energy storage systems can help stabilize the grid
Many energy companies struggle to reliably deliver power at stable voltages during extreme heat waves and cold snaps. Additionally, high-energy applications such as artificial intelligence (AI), industrial manufacturing, and electric vehicle (EV) … [Read more...]
What are the advantages of EV hairpin motors?
Hairpin motors optimize electric vehicle (EV) performance and range with flat, rectangular copper windings. Many high-performance EVs use permanent magnet synchronous motors (PMSMs) with hairpin windings to minimize energy losses and maximize power … [Read more...]
What is electric vehicle supply equipment (EVSE)?
Electric vehicle (EV) owners rely on electric vehicle supply equipment (EVSE) to charge their batteries efficiently. Often called charging stations or docks, EVSEs provide a reliable and safe connection between EVs, the electric grid, and other … [Read more...]
Why are adhesives important for EV thermal management?
Thermal adhesives ensure electric vehicle (EV) systems operate safely and efficiently by maintaining thermal conductivity and mechanical stability. This article discusses thermal adhesives' important role in key EV components such as lithium-ion … [Read more...]
How much could solid-state batteries improve EV range?
First-generation solid-state batteries are poised to boost the driving range of electric vehicles (EVs) by 50% to 80%. Solid-state batteries could extend this range even further, with some automotive manufacturers ambitiously targeting 900 to 1,000 … [Read more...]
Why high-power dc EV chargers require liquid cooling systems
Electric vehicle supply equipment (EVSE) typically incorporates air or liquid cooling systems to prevent overheating and maintain charging efficiency. This article explores the thermal challenges of electric vehicle (EV) chargers and the strategies … [Read more...]
How is lightweighting affecting EV component design?
Automotive manufacturers use a combination of advanced materials and innovative design techniques to reduce the weight of electric vehicles (EVs). Known as lightweighting, the process is crucial in optimizing EV performance, efficiency, and range. … [Read more...]
How do EVs reduce noise, vibration, and harshness?
Reducing the effects of noise, vibration, and harshness (NVH) is a top priority for electric vehicle (EV) manufacturers. Indeed, all critical EV systems, including electric motors and regenerative brakes, produce various forms of NVH as functional … [Read more...]
What are solid-state batteries, and how do they differ from current EV batteries?
Lithium-ion (Li-ion) battery traction packs power most electric vehicles (EVs) on the road today. These batteries enable electric motors to efficiently generate the high torque required for rapid acceleration and consistent speeds. Although Li-ion … [Read more...]