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...]
How are accelerated life tests changing for high-voltage EV power electronics?
For many years, standards such as AEC-Q101 and the "test-to-pass" method were the only ways to enter automotive power electronics. But since the powertrain has become electric, these static qualification methods are no longer enough. Electric … [Read more...]
Bonding dissimilar materials in EV structures
To offset the weight of battery packs in electric vehicles (EVs), manufacturers are adopting multi-material strategies that integrate advanced high-strength steels, aluminum alloys, and carbon fiber-reinforced polymers (CFRP). This Q&A addresses … [Read more...]
How do winding architectures impact transformer leakage inductance and parasitic capacitance?
Editor's note: Many of the transformer winding architectures discussed in this article are increasingly deployed in electric-vehicle (EV) power electronics, including onboard chargers, isolated dc-dc converters, and gate-drive power supplies. As EV … [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...]
Why is state of charge (SOC) becoming more complex in EVs?
State of charge (SOC) is often described as the electric vehicle (EV) equivalent of a fuel gauge. For EV engineers, that comparison only goes so far. In practice, SOC functions as a continuously estimated control variable that influences charging … [Read more...]
Rethinking EV development through integrated simulation
Electric vehicles (EVs) introduce architectural, dynamic, and acoustic challenges that differ fundamentally from internal combustion platforms. Battery mass, motor torque characteristics, structural loading, and high frequency noise, vibration, and … [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...]
How is physical AI used in autonomous and electric vehicles?
Physical AI (PAI) in autonomous and electric vehicles (EVs) involves systems that perceive the environment, make intelligent decisions, and execute appropriate actions in real-time, bridging the gap between digital intelligence and physical … [Read more...]
How AI Is accelerating atomistic simulation for EV battery materials
Electric vehicle (EV) battery teams need not be convinced that conventional lithium‑ion is running into practical limits. What they do need is a way to push beyond incremental tweaks to cathode blends or electrolyte additives, without waiting weeks … [Read more...]
How do inverter switching strategies influence battery health?
Editor’s note: Although the analysis references battery energy storage systems, the electrical behaviors and control strategies examined, particularly switching frequency effects and ripple-induced degradation, are directly relevant to electric … [Read more...]
Why isolation monitoring matters in high-voltage EV systems
Isolation monitoring is a safety function used in high-voltage electric vehicle (EV) systems to detect unintended electrical paths between energized conductors and the vehicle chassis. Electric vehicle high-voltage systems such as battery … [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...]
How advanced fluoromaterials are transforming EV wiring and cable systems
Electric vehicles (EVs) are reshaping mobility through cleaner energy and higher efficiency. However, achieving the potential of EV technology depends on continuous innovation in materials, especially those used in high-voltage wire and cable … [Read more...]
Part II: Why it’s important to be wary of “platform” and “modular” architectures
Part I of this series examined how large-scale platform modularity, particularly in EVs, can introduce design tradeoffs and system-level ripple effects once real engineering constraints appear. Promised flexibility often gives way to added … [Read more...]