Gasgoo, the world’s leading information service platform for the automotive industry, has unveiled the list of China’s 100 new automotive supply chains in the Gasgoo Awards 2022. The program will cover ten major areas: autonomous driving, smart cab, software, automotive chips, electrification, thermal management . , body and chassis, interior and exterior, lightening and new materials, and service providers.
In the field of powertrains, the 2022 Gasgoo Award attracted 33 companies and 41 technologies to be shortlisted for the top 100 Chinese automotive supply chain companies. Here are some details about them.
AAM’s T Series 2-in-1 e-beam axles feature lightweight welded differentials, die-cast aluminum housings, coaxial gearboxes, and welded tube technology to address electrification-related design challenges, including overweight, overhang quality, layout. effects. This e-Beam axle can provide electrification solutions for pickup trucks, vans, SUVs, minivans and light logistics vehicles without compromising loading and towing capacity. Our first e-beam product for the Chinese T4500 delivers 4500Nm of torque with an axle 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 become a hot topic. The most intuitive and efficient solution for commercial vehicle electrification is axle electrification. With the development of the urban process, smaller, lighter and more efficient electric bridges are undoubtedly the main market trend.
Today, all countries in the world are accelerating the energy transition from fossil energy to clean energy in order to achieve sustainable development. Transportation is a key area of ​​energy transition, and batteries are the key to electrification. The world’s largest automotive companies have announced increased investment in electric vehicles, leading to an explosion in the production of lithium-ion batteries. 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 batteries, it can not only reduce the weight of the battery, but also give it an energy density that exceeds the density of lithium-ion batteries. Therefore, lithium metal batteries are considered to be the ultimate goal of batteries.
The SES lithium metal battery uses the same positive electrode material as a conventional lithium ion battery, but the negative electrode is changed from graphite to lithium instead of needle structures that easily pierce the baffle. 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 improve energy density: 1. Better anode 2. Better cathode 3. Fewer inactive materials 4. Packing efficiency. While most lithium-ion battery improvements to date are based on points 2, 3, and 4 above, little has changed in the energy density of the anode, which is still mostly graphite (a form of carbon). Anodes can be more disruptive than the constant incremental innovations that keep being introduced into the cathode and other parts of the cell 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 automotive lithium metal battery. Preliminary test data: 107 Ah, 0.982 kg, 417 Wh/kg and 935 Wh/l. It is currently the largest lithium metal battery in the world. SES is currently optimizing devices of this specification.
In addition, SES lithium metal batteries can maximize the traditional lithium ion battery manufacturing process to reduce uncertainty.
With its leading lithium metal battery technology, SES has attracted the attention of many major automotive companies. SES has signed an agreement to co-develop the Model A with General Motors, Hyundai Motor and Honda, which is the world’s only three lithium metal JDAs to date.
Electrification is accelerating, but this is just the beginning. Once the lithium metal battery with higher energy density and higher performance is commercialized, it can successfully facilitate not only the production of long-range electric vehicles, but also electric vertical takeoffs and landings, intercontinental electric aircraft and electric trucks, etc.
SES is gearing up for mass production of lithium metal batteries in 2025. In terms of cellular technology, we are at stage A and will gradually move to B and C over the next few years. In terms of production, starting in the second half of 2021, SES is expanding its factory in Jiading, Shanghai. The first expansion phase will be completed in March 2022 with a capacity of 0.2 GWh. When the second phase is completed in 2023, the facility will have a capacity of 1 GWh and is expected to be the largest lithium metal battery plant in the world.
The NVXR17S90M2SPB is a silicon carbide (SiC) power module from the VE-Trac™ Direct SiC family of highly integrated power modules in an industry standard package for hybrid and electric vehicles (HEV) with a traction inverter. The module uses Onsemi 900V 2nd generation SiC MOSFET technology in a 6 block configuration with low on-resistance (1.7mΩ) for higher levels of performance, efficiency and quality. New generation crimp contacts are integrated into the signal terminals of the Power Module for easy and reliable assembly. In addition, it integrates an optimized pin heatsink into the base plate. To improve reliability and thermal performance, sintering technology is used to secure the die.
3) Direct cooling with built-in Pin-fin heatsink and sintering technology to further improve thermal performance and reliability.
Designed for EV/HEV traction inverters, VE-Trac Direct SiC converts battery power into massive torque and acceleration. Silicon carbide power modules can provide electric vehicles with longer range, higher efficiency and faster acceleration.
VE-Trac products, including the previously introduced VE-Trac Dual and VE-Trac Direct platforms, are available with silicon IGBTs and SiCs in a variety of voltages, and traction inverter power from 100kW to 250kW. With standardized mechanical dimensions and increased power ratings, the VE-Trac family of products makes it easy to increase EV power output, accelerating the adoption of EVs and hybrid EVs.
The compact 800V iDM consists of an electric motor, inverter and gearbox that help to increase the range, handling and safety of electric vehicles.
The compact iDM 800V offers a high degree of integration and efficiency, covering power needs from 160 kW to 300 kW, with a maximum torque of up to 5500 Nm. The 800V SiC Inverter Power Modules use BorgWarner’s proven two-way water-cooled Viper module technology to reduce semiconductor size and increase efficiency. The proven application of the patented Viper provides 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 current system has reached ASIL C in accordance with the ISO 26262 standard and is fully compatible with upgrades to ASIL D. The software also has network security features. As for the motor, the 800V high voltage hairpin (HVH) has a compact design with an outer diameter of 220mm and a maximum speed of over 20,000rpm. With a scalable and innovative design, the high power density HVH can achieve high power output in a compact package.
800V allows for more flexible solutions to optimize powertrain systems, offering more options including longer range or smaller batteries, ultra-fast charging stations will be smaller, lighter and cheaper in cables, and more energy recovery from braking for further increase in power reserve.
Shunt IBS continuously analyzes the health of conventional 12V lead-acid batteries and provides information on key parameters such as charge level, functional state (capacity) and health state (aging) of the battery. Therefore, sensors are necessary for the reliable operation of the car’s start-stop system. The IBS attaches directly to the battery and fits perfectly into the niche around the negative terminal.
As a key component of the start/stop system, IBS is a key solution for reducing carbon emissions in fuel-burning vehicles. It is also used to manage 12V batteries in new energy vehicles, backup battery systems and ADAS steering also require IBS. In line with China’s carbon neutrality strategy.
1) Through a reasonable electromechanical clutch layout design, develop integrated range extender products, adapt to the engine displacement of various new energy vehicles, improve fuel economy and emissions of extended range electric vehicles, help the industry save energy and reduce emissions. , and improve the driving experience of users.
2) Realize the design concept of platformization, light weight and compactness to meet the space adaptation requirements of various new energy vehicles;
3) In combination with the working conditions of the whole vehicle, the connection of the engine assembly and engine system of the extended range engine with high efficiency and low fuel consumption is completed, so as to improve the efficiency of the extended range 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 realized various layout forms to meet the needs of different vehicles. Among them, this is the first time in China that the inclined model is equipped with a new energy vehicle.
3) Implemented the connection between the range extender engine crankshaft and the split range engine assembly, which greatly reduces the axial size of the whole machine and ensures compactness and light weight.
4) The sealing structure of the connection surface between the engine and the generator for the range extender is designed so that the high pressure system of the range extender can reach IP67 protection level.
5) Develop a stand for testing range extenders, formulate test methods for reliability and durability and apply them in technology.
In accordance with the “Regulations on the Management of Investments in the Automotive Industry” issued by the National Development and Reform Commission, in order to promote the development of new energy vehicles in my country, long-range electric vehicle investment projects have been transformed from state-owned – market-oriented. Most car companies have developed extended range models. The market potential for the expanded capacity program 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 all-in-one solution is easy to install while still sealing and wiring.
In addition, the conductive non-woven material can also be specially used as a conductive ring to adapt to different installation spaces with extremely low frictional power loss and a greatly extended service life.
1) Can be combined with gland without additional space or modification. Easy and reliable installation, sealing and electrical conductivity.
2) The customized design is flexible and can be used as a pure ground ring or combined with various sealing systems suitable for various applications such as water/oil cooling systems.
Electric drive system (motor) reduction of shaft voltage/current, protection of bearings against electrical corrosion, protection against electromagnetic interference
With the trend towards medium and high voltage electrical power platforms, there is an increasing focus on shaft stress, galvanic bearing corrosion and electromagnetic interference. The eCON conductive non-woven grounding component, innovatively developed by NOCK-Freudenberg (China), is a safe, reliable, flexible and economical solution for the entire life of electric vehicles.
With the advancement of macroeconomic policies and the rapid growth of demand in the automotive and energy storage industries, battery safety is becoming more and more important.
From a technical standpoint, 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; both involve balancing to ensure every battery is the same. strength. In order to achieve faster charging, get more accurate information about the current state of battery cells, and improve battery cell safety, innovative design of battery management systems and BMS devices is required so that battery system designers can understand the deep state of the battery. , optimize battery usage, increase battery power limits, and anticipate security risks well in advance. Therefore, developers are more and more eager for the EIS (Electrochemical Impedance Spectroscopy, EIS, Electrochemical Impedance Spectroscopy) measurement function.
In the prior art, to ensure the safe operation of the battery, it cannot operate at the maximum charge and discharge parameters during charging and discharging, because the current BMS control system does not support EIS (electrochemical impedance spectroscopy, EIS for short, electrochemical impedance spectroscopy). Therefore, the well-known EIS model (Electrochemical Impedance Spectroscopy, EIS) cannot be applied to a real algorithm, it is impossible to accurately assess the health status of a battery, and electrical thermal runaway warning cannot be made.
Our ICMU product supports voltage detection, temperature detection and EIS measurement of cells, and uploads measurement data to the main control center via daisy chain. Based on the voltage, temperature and EIS data collected, the main control center can compensate for the shortcomings of the existing BMS system functions.
So next time, the BMS system that supports the EIS function will definitely become the market leader.
The new high-voltage energy vehicle wiring harness based on automated intelligent manufacturing, meets the vehicle’s 400-800V electrical system, realizes the requirements of the platform application from A0 to D level, meets the strict requirements of 3D high-voltage wiring harness layout, and meets the electrical performance of the car , reducing the need for high-voltage plug-in types, reducing the number of sub-components per plug-in, and realizing the product platform and smart manufacturing.
In terms of digital design and implementation, we can help customers complete the development of a complete data platform integrating design, engineering, process, and manufacturing, reduce development costs and cycle time, and establish and improve product lifecycle management.
Reduce labor, shorten cycle times, reduce manufacturing costs, improve product quality, and accurately track individual data to enable 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 models, especially the combination of early platform, ultra-high voltage platform development, standardized design in the new architecture stage, and automated intelligent manufacturing.
Significantly improve the production capacity level, quality control level, ability to control production costs, product life cycle traceability and other aspects of traditional new wire harness technologies, greatly reduce labor costs and production costs, and break the traditional labor-intensive industrial processing system for the design of high-voltage harnesses wires.
Product: High-density fuel cell platform technology for passenger cars and commercial vehicles