Gasgoo, the world’s leading information service platform for the automotive industry, has kicked off the grand Gasgoo 2022 ceremony. The top 100 list in China’s new automotive supply chain will cover ten major sectors such as autonomous driving, smart cab, software, and automotive chips. , electrification, thermal management, body and chassis, interior and exterior, lightweight and new materials, and service providers.
In the field of powertrain, 33 companies and 41 technologies were invited to the Gasgoo Awards 2022 and applied to be among the top 100 companies in China’s new energy vehicle supply chain. Here are some details about them.
AAM’s 2-in-1 e-beam T-Series axles use lightweight welded differentials, die-cast aluminum housings, co-axial gearboxes, and welded tube technology to address electrical displacement design challenges, including overweight, overhang mass, packing difficulties and negative impact on vehicle handling. . This e-Beam axle can provide an electrification solution for pickup trucks, vans, SUVs, minivans and light logistics vehicles without compromising loading and towing capabilities. Our first e-beam product for China, the T4500 delivers 4500Nm of torque with a shaft weight of just 130kg, much lighter than other competitors.
As the electrification of passenger cars is gradually moving in the right direction, the electrification of commercial vehicles has also become a hot topic. The most intuitive and efficient solution for commercial vehicle electrification is axle electrification. With the development of urbanization, smaller, lighter and more efficient electric bridges are undoubtedly the main market trend.
Today, countries around the world are accelerating energy transformation, moving from fossil energy to clean energy, and achieving sustainable development. Mobility is a key area of ​​the energy transition, and batteries are the key to electrification. The world’s largest automotive companies have consistently announced increased investment in electric vehicles, fueling an explosive growth in lithium-ion battery production. However, after more than 30 years of development, traditional lithium-ion batteries have gradually reached a performance bottleneck, especially the limitation of energy density, which greatly limits the range of vehicles.
Lithium is the lightest metal element on the periodic table. Applied to the battery, it can not only reduce the weight of the battery, but also give it an energy density that is superior to that of a lithium-ion battery. Therefore, lithium metal batteries are considered battery terminators.
SES lithium metal batteries use the same positive electrode material as conventional lithium ion batteries, but the negative electrode is changed from graphite to lithium. stable, fundamentally changing the nature of the growth of lithium dendrites, there will no longer be needle structures that can easily pierce the septum. In addition, SES solutions for lithium metal batteries include artificial intelligence software that monitors the condition of the battery and provides advance warning of battery anomalies weeks or more before a potential accident occurs.
SES lithium metal batteries combine the high energy density of solid state lithium metal batteries with the high processability of conventional lithium ion batteries. There are four ways to increase energy density: 1. Improved anodes 2. Improved cathodes 3. Fewer inactive materials 4. Packing efficiency. While most of the improvements in lithium-ion batteries to date have come from 2, 3, and 4 above, there has been little improvement in the energy density of the anode, which is still mostly graphite (a form of carbon). The anode is likely to be more damaging than the current incremental innovations that continue to occur in the cathode and other parts of the battery to improve overall efficiency. While the energy density of traditional lithium-ion batteries is 260-280 Wh/kg, lithium metal batteries start at 400 Wh/kg.
In November 2021, SES launched the world’s first lithium metal battery for cars. Preliminary test data: 107 Ah, 0.982 kg, 417 Wh/kg and 935 Wh/l. It is the world’s largest lithium metal battery. SES is currently optimizing cells for this specification.
In addition, SES lithium metal batteries can make the most of traditional lithium ion battery production processes to reduce the uncertainty that exists in them.
With its leading lithium metal battery technology, SES has attracted the attention of many major automotive companies. SES has signed A-model co-development agreements with General Motors, Hyundai and Honda, totaling just three lithium metal JDAs in the world to date.
Electrification is accelerating, but this is just the beginning. Once safer lithium metal batteries with higher energy density and higher performance are commercialized, they may not only successfully facilitate the production of long-range electric vehicles, but also power the vehicles of the future. such as eVTOL, intercontinental electric aircraft and electric trucks. Wait.
SES is gearing up for mass production of lithium metal batteries in 2025. In terms of cell technology, we are in the A-pattern stage and will gradually transition to B-pattern and C-pattern in the next few years. In terms of production and production, starting from the second half of 2021, SES will expand its factory in Jiading, Shanghai. The first phase of the expansion project will be completed in March 2022 with a production capacity of 0.2 GWh. After the completion of the second phase in 2023, the plant’s production capacity will reach 1 GWh and it is expected to become the world’s largest lithium metal battery plant.
The NVXR17S90M2SPB is a silicon carbide (SiC) power module from the VE-Trac™ Direct SiC series of highly integrated power modules in a standard form factor for hybrid and electric vehicles (HEV) with a traction inverter. The module integrates onsemi’s 2nd generation SiC MOSFET 900V technology in a 6-package configuration with low on-resistance (1.7mΩ) to achieve a new level of performance, efficiency and quality. New generation crimp contacts are built into the signal terminals of the power module to simplify assembly and improve reliability. In addition, an optimized pin heatsink is integrated into the case. To improve reliability and thermal performance, sintering technology is applied to the chip mounting.
3) Direct cooling with integrated pin heatsink and sintering technology to further improve thermal performance and reliability.
Specially designed for EV/HEV traction inverters, VE-Trac Direct SiC converts battery power into huge torque and acceleration. SiC-based power modules provide longer range, higher efficiency and faster acceleration for electric vehicles.
VE-Trac products, including the previously released VE-Trac Dual and VE-Trac Direct platforms, are available in silicon IGBTs and SiCs with various voltages for traction inverter power from 100kW to 250kW. With standard mechanical dimensions and increased power ratings, the VE-Trac product family allows for easy scaling of EV power output, thereby accelerating the adoption of EVs and hybrid EVs.
The compact 800V iDM consists of an electric motor, inverter and gearbox to help increase the range, handling and safety of electric vehicles.
The compact 800V iDM is highly integrated and efficient, delivering power from 160kW to 300kW with maximum torque up to 5500Nm. The 800V SiC Inverter Power Module uses BorgWarner’s proven two-way water-cooled Viper module technology to reduce semiconductor size and increase efficiency. The proven application of the patented Viper ensures greater reliability and adaptability. High efficiency high voltage stud motor and oil cooling system design ensure competitive performance and stable power of the electric drive system.
The system has now reached the ASIL C level defined by the ISO 26262 standard and is fully compatible with the upgrade to ASIL D. The software also has cyber security features. As for the electric motor, the 800V high voltage hairpin (HVH) has a compact design with an outer diameter of 220 mm and a maximum speed of over 20,000 rpm. With a scalable and innovative design, the high power density HVH can achieve high power output in a compact package.
The 800V voltage allows for more flexible solutions to optimize the powertrain system, providing more options, including longer range or smaller batteries, ultra-fast charging stations will be smaller, lighter and cheaper on cables, and more energy recovery when braking will further extend the driving range .
The IBS shunt continuously analyzes the condition of a conventional 12V lead-acid battery and provides information on key parameters such as state of charge, functional state (load capacity) and health state (aging) of the battery. As such, sensors are critical to the reliable operation of automotive start-stop systems. The IBS mounts directly to the battery and fits snugly into the niche around the negative terminal.
As a key component of the start/stop system, IBS is a key solution for reducing fuel-fueled CO2 emissions. Also used to control the 12V battery of new energy vehicles, backup battery system and ADAS steering, IBS is also required. In line with China’s carbon neutral strategy.
1) Develop integrated range extension products with reasonable electromechanical clutch layout, adapt to the engine size of various new energy vehicles, improve fuel economy and emissions of long range electric vehicles in range extension mode, help the industry save energy. and reduce emissions as well as improve the user’s driving experience.
2) Realize platform, light and compact design concepts to meet the space adaptation requirements of various new energy vehicles;
3) In combination with the working conditions of the whole vehicle, complete the connection of the engine assembly and the range extending propulsion system with high efficiency and low fuel consumption, improve the efficiency of the range extending system, and realize industrialization.
1) Learn the range extender durability test method, realize the engineering application and improve the reliability of the product:
2) Based on the platform design concept, the whole machine has various layout shapes to meet the needs of different vehicles. Among them, this is the first time in China that a tilt vehicle is equipped with a new energy vehicle.
3) The connection between the range extender engine crankshaft and the split type range extender engine assembly is realized, which greatly reduces the axial size of the whole machine and ensures compactness and light weight.
4) Research and develop the sealing structure of the range extender motor and generator special connection surface, so that the range extender high-voltage system can achieve the IP67 protection level.
5) A bench for testing the range extender has been developed, and methods for testing reliability and durability have been formulated and applied in technology.
In accordance with the regulations on the management of investment in the automotive industry issued by the National Development and Reform Commission, the investment project for the production of extended range electric vehicles will help transform the development of new energy vehicles in China from state power to market power. were developing extended range models. The potential is huge.
eCON – Conductive Non-woven Components – is an innovative solution for protecting bearings from galvanic corrosion and electromagnetic interference.
Specially treated nonwovens can provide good electrical conductivity. Combined with oil seals, the complete solution is easy to install and provides sealing and electrical conductivity.
In addition, the conductive nonwovens can also be specially used as conductive rings to adapt to different installation spaces with extremely low frictional power loss and greatly extended service life.
1) Can be combined with gland without additional space or modification. It is simple and reliable in installation, performs the functions of sealing and wiring at the same time.
2) The customized design is flexible, it can be used as a pure ground ring, or combined with various sealing systems, suitable for various applications such as water / oil cooling systems.
Drive system (motor) shaft voltage/current reduction, bearing erosion protection, EMI protection
With the trend of medium and high voltage motorized platforms, more attention is being paid to the problems of shaft voltage, bearing corrosion and electromagnetic interference. NOK-Freudenberg (China) has developed an innovative eCON solution, a conductive non-woven ground component, which is a reliable, flexible and cost-effective solution for a lifetime warranty for electric vehicles.
With the advancement of macroeconomic policies, the demand in the automotive industry and energy storage is growing rapidly, and battery safety is becoming more and more important.
From a technical point of view, new energy vehicles and energy storage systems share similarities in electronic monitoring and battery management: both include voltage and temperature monitoring to ensure battery safety; battery power is the same. In order to achieve faster charging speed, get a more accurate current state of the battery, and improve the safety of the battery, it is necessary to develop an innovative battery management system and BMS equipment so that battery system designers can understand the deep state of the battery. , optimize battery usage, increase battery power limit, and predict security risks in advance. Therefore, developers are increasingly striving for the function of EIS (Electrochemical Impedance Spectroscopy, EIS, Electrochemical Impedance Spectroscopy).
In the prior art, in order to ensure the safe operation of the battery, it cannot operate at the maximum charge and discharge parameters during the charge and discharge process, since the current BMS control system does not support EIS (electrochemical impedance spectroscopy, referred to as EIS), electrochemical impedance spectroscopy). Therefore, it is impossible to apply the well-known EIS model (Electrochemical Impedance Spectroscopy, EIS, Electrochemical Impedance Spectroscopy) to the real algorithm when executing the algorithm, and it is impossible to accurately assess the health status of a battery cell, and it is impossible to make an electrical thermal runaway warning.
And our product: ICMU, supports battery voltage detection, temperature detection and EIS measurement, and uploads measurement data to the main control center through daisy chain. With voltage, temperature and EIS data collected, the main control center can fill the lack of functionality of the existing BMS system.
So next time, the BMS system supporting the EIS function will surely become the market leader.
The new high-voltage energy vehicle wiring harness, based on automated intelligent manufacturing, matches the vehicle’s 400-800V electrical system, realizes the requirements of the platform application from A0 to D level, meets the strict requirements of the 3D high-voltage wiring harness layout, and meets the electrical characteristics of the car , reducing the need for high-voltage plug-in modules. The types and number of sub-components of each plug-in to realize the platformization and smart manufacturing of products.
In terms of digital design and implementation, help customers complete the development of a complete data platform integrating design, engineering, technology, and manufacturing, reduce development costs and cycle time, and establish and improve product lifecycle management.
Reduce labor, shorten production cycle, reduce production costs, improve product quality, and track customized accurate data to provide full lifecycle data management of high voltage wiring harnesses for new energy vehicles.
Adapt to the replacement of multi-variant, small-scale and labor-intensive production methods, especially the combination of early platform, ultra-high voltage platform development, normalized design in the new architecture stage, and automated intelligent manufacturing.
Greatly improve the production capacity of traditional new energy harnesses, quality control level, ability to control production costs, product life cycle traceability and other technologies, radically reduce labor costs, production costs, and break the traditional labor-intensive structure of industrial processing system. voltage wiring harnesses.
Products: High density fuel cell platform technology for passenger and commercial vehicles