Electric vehicle (EV) connectors must operate reliably despite intense vibration, thermal cycling, moisture exposure, and elevated temperatures. Adhesives and sealants applied to connector housings, cable entries, and termination points significantly … [Read more...]
Optimizing EV motor design with advanced materials and AI
Electric vehicle (EV) motor design continues to evolve as manufacturers target higher power density, greater efficiency, and seamless system integration. This article reviews optimization strategies for EV motors, focusing on material innovations, … [Read more...]
Shifting LEVs to higher voltages: Performance gains and safety challenges
Many light EV (LEV) manufacturers are shifting from traditional 36 to 48-Volt (V) architectures to higher-voltage powertrains in e-bikes, scooters, mopeds, and neighborhood electric vehicles (NEVs). Operating between 72 and 96 V (and above), these … [Read more...]
What engineering requirements shape EV high-voltage connectors and contactors?
High-voltage electric vehicle (EV) connectors and contactors must comply with a wide range of electrical, thermal, mechanical, and safety requirements. Engineers select these components for current capacity and switching performance, then refine … [Read more...]
What is the role of engineering coatings in EVs?
Electric vehicle (EV) manufacturers use specialized coatings to provide electromagnetic interference (EMI) shielding, environmental protection, and controlled thermal pathways across high-voltage electronics, battery packs, and cooling … [Read more...]
Testing EV subsystems across multiple voltage domains
Electric vehicle (EV) architectures span multiple voltage domains, combining 400 or 800 V traction systems with 48-V auxiliary networks and 12-V electronics. The mix of voltage levels increases the complexity of testing traction inverters, dc-dc … [Read more...]
Designing EV powertrains for high voltage and ultra-fast charging
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...]