High-power electric vehicle (EV) charging adds complexity well before power reaches the battery. A vehicle that must handle Combined Charging System (CCS) and Megawatt Charging System (MCS) inputs may need a separate charge controller for each inlet. … [Read more...]
Designing safety into the cell: The case for system-level solid-state batteries
Electric vehicle (EV) battery design keeps colliding with the same problem. Higher energy density can extend range, but it can also raise the risks tied to safety and thermal management. Solid-state batteries come up often as a way forward, though … [Read more...]
How direct cell contact is changing EV battery cooling
Electric vehicle (EV) battery packs must charge faster, deliver more power, and hold more energy, all without much additional room inside the pack. Much of that engineering challenge now centers on the cooling interface between the cell and the … [Read more...]
Why high-voltage interconnect design is becoming critical in EV battery systems
Battery pack development leans heavily on cell chemistry, with thermal management and energy density close behind. However, high-voltage interconnect systems are becoming increasingly important to pack performance and long-term reliability as … [Read more...]
Rethinking power design for distributed EV architectures
Electric vehicle (EV) power systems are under increasing pressure to deliver higher efficiency and performance within tighter space constraints, particularly as more functionality is added across the vehicle. This is making power delivery more … [Read more...]
Designing lithium battery systems with built-in fire suppression
Electrified platforms continue to advance, placing increased focus on battery safety at the system level. While much of the focus in electric vehicles (EVs) is placed on thermal management and battery management systems (BMS), alternative approaches … [Read more...]
The importance of energy metering for megawatt EV charging systems
Electric vehicle (EV) charging infrastructure is moving toward higher power levels, including megawatt-class systems designed for heavy-duty trucks and buses. These charging environments require highly accurate energy measurement for billing, … [Read more...]
A “drop-in” material for higher battery performance
Electric vehicle (EV) battery development has faced a balancing act. Increase energy density and you often sacrifice cycle life. Improve fast charging and thermal stress increases. Adopt a novel material and manufacturing complexity … [Read more...]
Addressing EV structural demands with composites
Electric vehicle (EV) platforms place distinct demands on body structures. Battery packs increase overall vehicle mass while introducing strict crash-energy management and load-path requirements. At the same time, skateboard architectures and … [Read more...]
Why integrated EDUs are reshaping electrified drivetrain development
Electrified drivetrain development is increasingly constrained by higher voltage architectures, tighter packaging envelopes, and rising efficiency expectations. At the same time, validation cycles for motors, inverters, and gearsets are becoming … [Read more...]
Why deterministic testing matters in high-voltage EV systems
Efficient electric vehicle (EV) development depends on validation cycles that are faster, more repeatable, and more controlled than traditional manual testing can provide. Today’s EV modules operate as tightly integrated electronic and software … [Read more...]
Inductive charging is moving from roadways to driveways
Inductive charging, once limited to small electronic devices like smartphones, is slowly becoming a reality for electric vehicles (EVs). In Detroit, for example, a short section of 14th Street was fitted with embedded coils that wirelessly recharge … [Read more...]
How bidirectional charging turns EVs into energy assets
Bidirectional charging is redefining the boundary between electric vehicles (EVs) and the grid. Once seen solely as energy consumers, EVs are now becoming distributed energy resources capable of powering homes, supporting grids, and enhancing energy … [Read more...]
Battery sensor enhances early detection of thermal events in EVs
Metis Engineering’s Cell Guard is an advanced sensor that provides real-time insight into the condition of lithium-ion battery packs. Designed to extend pack longevity and safety, it detects cell venting, the earliest sign of catastrophic battery … [Read more...]
Why pressure sensing is critical to EV thermal management
Battery safety is one of the most demanding challenges in electric vehicle (EV) design. When mechanical, electrical, or thermal stress causes a cell to overheat, it can trigger thermal runaway, an uncontrolled chain reaction that leads to … [Read more...]
How electropolishing enhances EV component reliability
Electropolishing, sometimes described as reverse electroplating, is an electrochemical process that removes a controlled layer of surface material to eliminate defects and improve the finish of metal parts. Using an electrolyte bath and a dc current, … [Read more...]