A 400-V-class dc fast charger cannot directly charge an 800-V electric vehicle (EV) battery when its maximum output falls below the pack voltage. Driving current into the pack requires the source voltage to exceed the battery’s by enough to overcome … [Read more...]
How hydrogen fits into electric vehicle powertrains
Hydrogen is increasingly appearing in heavy-duty vehicle electrification, particularly in applications where battery capacity and charging infrastructure present challenges. Although hydrogen-powered trucks are often discussed separately from … [Read more...]
How do current-sensing errors propagate through EV motor control systems?
Torque decisions in an electric vehicle (EV) traction drive often start from two or three-phase current readings, which leaves little margin for current sensing errors. Field-oriented control (FOC) turns those readings into d-axis and q-axis … [Read more...]
EV Talk: Designing EV components with end of life in mind
Material selection plays an important role in the performance of electric vehicle (EV) components, but engineers are increasingly being asked to consider what happens to those materials long after a vehicle leaves production. In this episode of EV … [Read more...]
Mitigating high-frequency vibration in structural battery packs
Modern electric vehicle (EV) battery engineering revolves around removing layers of structure so more active cell material fits into the same footprint. Increasingly, the battery also becomes part of the vehicle’s load-bearing architecture. Along … [Read more...]
What causes bearing currents in EV motors and how engineers prevent them
An electric vehicle (EV) traction inverter can drive unwanted current through the motor bearings. Its switching creates voltage on the motor shaft, even without a direct electrical connection between the windings and rotor. If the voltage across a … [Read more...]
Probing considerations for double pulse testing SiC devices and modules
Editor’s note: Silicon carbide (SiC) power devices are widely used in electric vehicle (EV) traction inverters and other high-voltage power electronics. This article discusses probing considerations for double-pulse testing SiC devices and modules, … [Read more...]
Five trends shaping conductive additives in batteries
Conductive additives make up a small portion of a battery electrode, yet they play a significant role in cell performance. Ahead of The Battery Show, Orion S.A. outlined five trends that are reshaping how conductive additives are used in lithium-ion … [Read more...]
How do two-level and three-level inverter topologies compare in EVs?
Whenever an electric vehicle (EV) battery bus exceeds 400 V, it poses powertrain design challenges for engineers. One of the key design challenges is the choice of inverter topology, whether a two-level or a three-level inverter topology. Though a … [Read more...]
How does fault-tolerant control keep an EV operating after a sensor failure?
The rotor in an electric vehicle (EV) traction motor delivers torque through the motor shaft to the drivetrain. A rotor-position sensor, such as a resolver, reports the rotor angle needed for accurate torque control. If the sensor fails, … [Read more...]
How motor selection shapes system performance
Electric motor selection often starts with datasheet ratings like peak power, torque, and speed range. These values are required for design, but they aren't sufficient on their own. In an electrified or hybrid platform, the motor doesn't operate in … [Read more...]
Why e-axle fluids have become an EV engineering problem
Electric vehicle (EV) drive units keep getting smaller and more integrated, and that's changed what the fluid inside them has to do. In a conventional gearbox, lubricant selection mostly comes down to protecting the gears while keeping friction … [Read more...]
How to catch EV faults before they become failures
Most electric vehicle (EV) battery failures do not happen out of nowhere. Long before a pack trips into a protective shutdown, there are usually small signs sitting quietly in the data, a cell running a few millivolts higher than its neighbors, or a … [Read more...]
How do busbar design and stray inductance affect EV power electronics?
Silicon carbide (SiC) or gallium nitride (GaN) switching operations are limited by the busbar stray inductance because the inductance is present in the commutation loop. It's through the commutation path that current travels through the dc bus … [Read more...]
Engineering reliable charging hubs for autonomous EV fleets
Autonomous ride-hailing fleets need somewhere to recharge between trips, and that’s often a dedicated charging hub rather than a public station. These hubs can look a lot like large dc fast charging sites, but they’re used very differently. A … [Read more...]
How is EV charging interoperability tested?
A connector that physically fits an electric vehicle (EV) inlet does not guarantee a safe, successful charging session. Electrical or communication differences can halt energy transfers, while backend issues may prevent authorization or transaction … [Read more...]