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 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...]
How to accelerate film capacitor design with simulation
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...]
Q&A: How standardized imaging can improve battery material characterization
Reactive alkali metals such as lithium and sodium are increasingly important to battery development. Their sensitivity to air, moisture, and electron beams makes them difficult to characterize without altering the structures researchers are trying to … [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...]