Editor’s note: Film capacitors are critical to electric vehicle (EV) power-electronics systems, particularly in dc-link and inverter applications, where component behavior can directly affect efficiency and reliability. This article looks at how … [Read more...]
How can EV systems be reliably tested for cybersecurity vulnerabilities?
Electric vehicle (EV) cybersecurity testing is performed throughout the vehicle development lifecycle. EVs can contain dozens of electronic control units (ECUs) and a battery management system (BMS), communicating over the controller area network … [Read more...]
How do high-voltage interlock loops protect EV electrical systems?
Hybrid and electric vehicle (EV) powertrains carry high-voltage circuits, often rated at 400 volts (V) and rising to 800 V on newer platforms. In this case, a single connector that separates while the circuit is still live can create an arc across … [Read more...]
Where force and torque measurement matters in vehicle validation
Simulation gives automotive engineers a way to evaluate vehicle designs before physical prototypes are built. The value of those models depends on how closely they match what happens in the real world. Live testing provides the measured data … [Read more...]
How brake-by-wire is changing regenerative braking control and validation
Regenerative braking gives an electric vehicle (EV) another way to slow down while returning energy to the battery. In some EVs, regenerative braking already handles most routine braking events, leaving the friction brakes to step in when more … [Read more...]
What is connector derating, and why does it matter in EVs?
Connector derating is a common engineering technique that reduces allowable current below the datasheet value to account for real-world operating conditions. This article explains how electric vehicle (EV) engineers determine a working current … [Read more...]
Part II: Inside the engineering of a magnet-free EV motor
In this two-part series, we examine the engineering behind a rare-earth-free electric vehicle (EV) motor and the trade-offs involved in replacing permanent magnets. Part 1 looked at the supply-chain case for magnet-free motors, the wound-rotor … [Read more...]
How are EV battery packs tested for leaks?
Electric vehicle (EV) battery packs must resist water ingress and retain coolant while maintaining electrical isolation. This article explores how automotive engineers verify sealing integrity across three areas: the pack enclosure, coolant circuit, … [Read more...]
How duty cycle determines battery life in off-highway EVs
Charge-discharge cycles and calendar aging limit battery life, but operating hours measure neither. For electric vehicle (EV) engineers, that distinction matters because service-life estimates influence how batteries are sized and managed throughout … [Read more...]
Part I: Why rare-earth-free EV motors are difficult to build
To understand the modern electric vehicle (EV), it helps to look beyond the touchscreen dashboard, the battery skateboard, and the software updates delivered over the air. Deep inside the powertrain is a component that has changed relatively little … [Read more...]
Why megawatt charging demands a new approach to testing
Every facet of mobility is undergoing a transformation toward more electric and autonomous transportation. For the freight industry to make this leap, megawatt charging needs to be readily available. However, delivering at the required scale adds … [Read more...]
How do engineers correlate dynamometer testing with real-world EV range?
When testing electric vehicles (EVs) for range in laboratories using a dynamometer, engineers often do not see the same EV's range on the road. So the first step is isolating each of the variables and studying how they impact EV range … [Read more...]
Why testing future EV batteries often begins with coin cells
When most people think about electric vehicle (EV) battery development, they picture large battery packs, cooling systems, and high-voltage cells destined for production vehicles. In reality, many EV battery technologies begin life in a laboratory … [Read more...]
How to manage creepage and clearance in high-density EV power modules?
Creepage and clearance provide the surface and air spacing needed to prevent tracking, arcing, and insulation breakdown in high-voltage power modules. As electric vehicle (EV) power density increases and battery pack voltages reach 800 V and beyond, … [Read more...]
How do engineers validate EV motors and inverters under representative duty cycles?
Motor inverter validation under representative duty cycles requires more than a steady-state load test. A drivetrain in service faces rapid torque swings, regenerative braking transients, and thermal cycling that a constant-load bench cannot … [Read more...]
How do EMC challenges differ for solid-state transformers and EV chargers?
Electromagnetic compatibility (EMC) challenges cut across many areas of power electronics. Solid-state transformers (SSTs) and electric vehicle supply equipment (EVSE) like EV chargers, face different EMC challenges because of their different … [Read more...]