ELVA-Innovative Architectures for Next Generation Electric Vehicles

Integrated Architectures for Third Generation Electric Vehicles – First Results of the ELVA Project

The shift from internal combustion (IC) engines to electric vehicles (EVs) marks a significant transformation in the automotive industry, prompting a comprehensive reassessment of various engineering considerations. Among these, tribological factors play a critical role in ensuring the performance, reliability, and longevity of vehicle components. This review examines the tribological challenges and opportunities posed by the transition to EVs, focusing on key components such as bearings, gears, and braking systems, which face unique operating conditions in electric powertrains compared to their IC counterparts. The paper addresses how electric vehicles encounter distinct tribological scenarios, such as lower operating temperatures but higher torque loads, which demand new materials and lubrication strategies. It also explores how the near absence of internal combustion in EVs affects component wear and the mechanisms of friction reduction. Additionally, the tribological challenges in IC engines are revisited to provide a comparative understanding of how they differ from those in EVs, particularly regarding energy efficiency and frictional losses. This review emphasizes the importance of minimizing wear and friction to maximize energy efficiency, which is crucial for extending vehicle range and improving performance in EVs. By synthesizing the latest research findings and industry advancements, the review offers valuable insights for researchers and engineers involved in the design and optimization of tribological systems for the next generation of electric vehicles.

A new generation of electric vehicles is being developed. A key problem to be solved is that of charging the batteries. One means of charging uses inductive coupling. The inductive coupling approach is essentially a transformer with a removable primary winding connected to a charging unit via a cable. The secondary and the core of the transformer are on the vehicle. This paper presents an inductive coupler which has been demonstrated delivering from 100 W to 120 kW continuously at a frequency of 75 to 120 kHz. The transformer is very compact (<100 in/sup 3/). The primary purpose of this paper is a discussion of the power transformer. In addition the paper briefly addresses how the design of a magnetic device, which is usually a strictly technical exercise between engineers, is impacted when it is directly accessible to consumers in a mass market.

A multifunctional energy storage composite (MESC) combines the high energy density of lithium-ion batteries with the structural benefits of carbon fiber composites, resulting in a lightweight structural battery with excellent mechanical strength and enhanced safety for electric vehicles (EVs). This paper presents the design-tofabrication development of new MESC, with a specific focus on the design, fabrication, and testing of an electronic skateboard (e-skateboard) as a representative system-level study for the EVs. A finite element analysis (FEA) is employed to design the MESC eskateboard. The FEA of the MESC e-skateboard is validated through mechanical testing, demonstrating a significant 24% reduction in weight, leading to an impressive 31.6% improvement in energy density compared to a conventional e-skateboard. As a part of the MESC technology, an embedded smart sensor network is also developed for the e-skateboard, showcasing the capability for real-time battery monitoring, and estimating its state of charge during in-service operation. The promising outcomes of the new MESC technology position it as a novel solution for enabling multifunctional structural battery composites in future electronic vehicles and aircraft applications.

<p indent="0mm">In order to deal with the increasingly severe global energy crisis as well as serious environmental pollution, it is urgent to develop new energy resources. Although lithium-ion batteries have only been successfully introduced into the market since 1990s, there is still an exponentially growing demand for lithium-ion batteries all over the world. As a considerable novel energy source, lithium-ion batteries have significant potential, which is widely used in electric vehicles, energy-storage systems, metallurgy, ceramic production, glass manufacturing and aviation fuel industries. Among them, the solid-state lithium-ion batteries (SSLIBs) represent a promising evolution in battery technology, offering superior safety, energy density, and longevity compared to conventional liquid electrolyte batteries. Traditional lithium-ion batteries, which use liquid electrolytes, suffer from safety issues such as leakage, flammability and thermal runaway. SSLIBs replace these liquid electrolytes with solid electrolytes, mitigating these risks and enabling higher energy densities due to the ability to accommodate lithium metal anodes. The SSLIB consists of a positive electrode, a negative electrode and a solid electrolyte. Compared with liquid electrolytes, solid electrolytes avoid the direct contact between positive electrodes and negative electrodes, fundamentally eliminating the risk of lithium dendrites piercing the separator, so as to enhance the safety of lithium batteries greatly. Furthermore, the SSLIBs are expected to be a hot spot in future lithium battery research due to the advantages of high energy density, wide operating voltage range and long cycle life. Advancements in SSLIBs technology are crucial for the next generation of electric vehicles, portable electronics, and large-scale energy storage systems, pushing the boundaries of battery performance, safety and sustainability. Solid electrolytes are regarded as the key component of SSLIBs, serving dual functions as both separators and electrolytes. The currently developed solid electrolytes can be divided into two categories: Polymer solid electrolytes and inorganic solid electrolytes, in which the oxide solid electrolytes, as the earliest developed inorganic solid electrolytes, play an indispensable role in the development of solid-state battery industry. The typical oxide solid electrolytes, including sodium super ionic conductor (NASICON), garnet (LLZO), inorganic perovskite (LLTO), and LiPON films, are reviewed in this paper. NASICON, for example, is known for its high ionic conductivity and structural stability. Garnet-type electrolytes, such as LLZO, possess high ionic conductivity and chemical stability with lithium. Inorganic perovskite (LLTO) provides a good balance between ionic conductivity and mechanical strength. LiPON films, widely used in thin-film batteries, have excellent electrochemical stability and compatibility with lithium metal. In addition, the crystal structures and ion-transport mechanism, the solutions to improve conductivity and measures to improve the compatibility between electrodes and electrolytes are introduced, along with a comparation of oxide solid electrolytes. Finally, several suggestions for future development directions are proposed. These include enhancing the ionic conductivity of solid electrolytes, improving the interface compatibility between the electrolytes and electrodes, and developing cost-effective and scalable manufacturing processes. Additionally, further research is needed to understand the degradation mechanisms and long-term stability of solid-state batteries. These recommendations aim to provide a more comprehensive reference for ongoing and future research on oxide solid electrolytes, supporting the broader goal of advancing solid-state lithium battery technology.

Development of lithium‐ion batteries (LIBs) with high energy density has brought a promising future for the next generation of electric vehicles (EV). In order to make EVs more competitive with combustion engine vehicles, development of an effective fast charging technique is inevitable. However, improper employment of fast charging can damage the battery and bring safety hazards. Herein, industry based along with our proposed internal resistance (IR) based fast charging techniques were performed on commercial Panasonic NCR 18650B cylindrical batteries. To further investigate the fast charging impact and electrode degradation mechanisms, electrochemical analysis and material characterization techniques including EIS (electrochemical impedance spectroscopy), GITT (galvanostatic intermittent titration technique), SEM (scanning electron microscopy), and XRD (X‐ray diffraction) were implemented. Batteries that were cycled under industry based fast charging showed 78% increase in internal resistance after 120 cycles along with rapid capacity fading. Mechanical distortion of the battery case occurred around the 60th cycle for industry based fast charging. In contrast, IR based fast charged batteries showed 29.4% increase in internal resistance over 120 cycles. In addition, mechanical distortion was not observed and the relative capacity fading was on a moderate level. Furthermore, this work could pave the way for the optimization of fast charging techniques to secure the lifespan and safety of various types of lithium‐ion batteries.

In this study, a high-power synchronous reluctance motor (SynRM) was designed for the traction motor of electric vehicle (EV) and its double-stage optimization was performed. Genetic algorithm and sensitivity analysis methods were used to obtain the best design parameters. Double-stage optimization was carried out to minimize the torque ripple and obtain the targeted torque, speed, and power values of the SynRM. In the first stage, the genetic algorithm method was used to improve the design parameters of the stator and rotor. With the improved design parameters, it was observed that the torque ripple decreased. In the second stage, the sensitivity analysis method was used. In this method, the effect of changing the skew angle of the stator on the torque ripple was investigated. The performance of the designed motor was examined in the optimization process. It was observed that the targeted torque, power, speed, efficiency, and torque ripple minimization values are successfully achieved with the best stator and rotor parameters. The results showed that SynRM produces high torque and high power with high efficiency and low torque ripple over wide speed range. It is quite proper to use the designed SynRM as a traction motor of new generation electric vehicles.

Scalable Room-Temperature Synthesis of Multi-shelled Na3(VOPO4)2F Microsphere Cathodes

Important factor in political decision-making is a public opinion as well. Therefore, it is very important to raise global ecological awareness and wider public education regarding ecology. Goal of this book is to bring closer to the readers new drive technologies that are intended to environment and nature protection. The book presents modern technique achievements and technologies applied in the implementation of electric vehicles. Special attention was paid to energy efficiency of EV's. Also today's trends, mathematical models and computer design elements of future cars are presented.

In recent years, there has been a noteworthy shift from conventional lithium-ion batteries using liquid electrolytes to solid-state batteries. Solid-state technology’s improved safety profile drives this shift due to the capability of solid-state electrolytes to reduce the risk of thermal runaway, leakage, and flammability. Furthermore, solid-state batteries present intrinsic resistance to dendrite formation, improved long-term stability, and reduced safety concerns. Recent advancements in using lithium and sodium solid-state technologies have been the foundation of a key innovation in this field. Lithium solid-state batteries exhibit the potential for higher energy density, faster charging, and longer cycle life. However, the high cost and the increased demand for lithium batteries raise concerns over environmental impacts and the availability of materials. Sodium solid-state batteries have the potential to be more sustainable and cost-effective as sodium is more naturally abundant. However, sodium batteries face challenges with lower energy densities and slower rate capabilities compared to the lithium system. Moreover, there is hesitation towards this technology as, in general, solid-state batteries face disadvantages in unstable cyclability, elevated operating temperature, mechanical weakness, and high interfacial electrode-electrolyte impedance. The scientific foundations of solid-state batteries and their improved effectiveness are solutions for the next generation of electric vehicles and grid-scale energy storage. Furthermore, an overview of ongoing research conducted at Dartmouth will be highlighted, including the utilization of solid composite electrolytes and the integration of high-performance sodium metal electrodes.

Solid polymer electrolytes (SPEs) are critical for the development of safe and high-performance solid-state lithium batteries that power the next generation of electric vehicles, drones, and robotics. To date, one of the major disadvantages of SPEs limiting their wide applications is their low ionic conductivity. The use of ionic liquids as plasticizers in SPEs has been demonstrated as a promising strategy to enhance the ionic conductivity of SPEs at room temperature while maintaining their safety features and mechanical properties. However, the optimization of plasticizers is largely intuition based without general design rules and predictive design strategies. Therefore, in this work, we developed a fast and low cost, data-driven workflow that advances the design and optimization of ionic liquid plasticizers for SPEs. Using this approach, we successfully identified a new plasticized SPE material that showed high ionic conductivity and superior cycling stability. Our data-driven model revealed that important design factors correlated to highly effective plasticizers, providing insights into the conduction mechanism of plasticized SPEs. More importantly, we found that these key factors are transferrable and applicable in other plasticized SPEs beyond our data set, highlighting the generality of the findings obtained by our data-driven approach.

The Data Time Flow Simulator (DTF) has been developed at the AIT Austrian Institute of Technology in the course of the EU ARTEMIS Project POLLUX which is related to the design of electronic control systems for the next generation of electric vehicles. In previous work, we have introduced a generic approach for performance analysis of vehicle electronic control systems using the DTF. The main issue of this paper is to demonstrate the practicability of this design methodology by means of a specific use case, namely the performance analysis of a vehicle control system for an electric city car, designed using inputs from different POLLUX project partners from the automotive industry.

Rechargeable Lithium ion batteries (LIBs), as a great promise power source for next generation electric vehicles such as electric vehicles (EVs). Demands for batteries with higher energy density, better cycle performance, lower cost and more safety are increasing. Graphite is mostly used as anode material for the commercial Lithium ion batteries with the theoretical specific capacity 372 mAh g-1 only. However, in order to overcome the lower capacity problem, many alternatives as anode materials are concerned including metals or metal sulfides. Recently, tin-based materials (e.g. Sn, SnO2, SnS) have been widely studied as anode materials because they have relatively high theoretical capacities, less toxic and low cost. In particular, tin sulfides has such as high theoretical capacity 782 mAhg1.However, the great volume expansion and the agglomeration of particles for the tin sulfides during the charge/discharge process could possibly result in pulverization of the electrode and thus to lead to rapid decrease in capacity and poor cycle life. Graphene or reduced graphene oxide (RGO), as one of the highly potential materials in lithium-ion batteries, is also used to be decorated with metal oxides or metal sulfides due to their high specific surface area, excellent electronic conductivity and porous structure. Therefore, an improved electrochemical performance can be achieved. More recently. Lots works have demonstrated that the incorporation of graphene within tin sulfide-graphene nanocomposites can provide a large area contact for tin sulfide particles and inhibit the volume change of tin sulfides, thus enhancing the electrochemical performance of tin sulfide-graphene nanocomposites. Thus, in this work, SnS/RGO nanocomposites was synthesized via a facile microwave-assisted method. The physical and electrochemical properties of the as-prepared nanocomposites were characterized by X-ray diffraction, scanning electron microscopy, transmission electron microscopy, thermogravimetric analysis, cyclic voltammetry, galvanostatic charge/discharge tests and electrochemical impedance analysis. Indeed, the SnS nanoparticles were successfully decorated on the surface of RGO, and the resultant SnS/RGO nanocomposite demonstrated an improved electrochemical performance because the incorporation of RGO provided a large area contact for SnS nanoparticles and inhibited the volume change of SnS during charge/discharge process.

The fast charging technology is an indispensable section in the development of the new generation electric vehicles, as it would provide a more convenient experience for customers during the usage. To achieve this technology, research works should be focused on both the fast charging infrastructure/station development as well as the lithium-ion (Li-ion) battery behaviors analyses during fast charging. In this paper, an electrochemical and thermal coupling model is implemented to simulate the battery performance under fast charging scenarios. More specifically, the effects of the battery internal parameters, such as electrode thickness and electrode electrical conductivity, on the electrochemical and thermal behaviors of the Li-ion battery during normal charges and fast charges are analyzed and discussed. The decrease of electrode thickness can to some extent alleviate the overpotential issue and improve the fast charging process, and it also significantly reduces the heat generation during the charging. Comparatively, increasing the electrical conductivity of the electrodes does not show any improvements on the battery fast charging.

The anticipation of high penetration of electric vehicles (EV) and renewable energy sources into future power grid brings up many technological problems that need to be addressed. This paper deals with the economic dispatch problem (EDP) for distribution systems with wind power and mixed-mode EVs. The developed stochastic models of different interactive modes between EVs and power systems are incorporated into EDP studies. A continuous action learning automata (CALA) was applied and verified in a modified IEEE 30 bus system which includes two wind farms, two battery exchange stations for EVs and distributed EVs penetration. The simulation results indicated the interaction between mixed-mode EVs and power systems can significantly reduce the gap between demand and power generation in different periods of time with optimal dispatch schedule.