battery electric vehicles Archives

Hyundai Motor Group unveils Electric-Global Modular Platform (E-GMP)

While still improving and innovating its technologies for models with internal combustion engines, the Hyundai Motor Group (HMG) is also investing substantially in battery electric vehicle (BEV) technology. Such vehicles will grow in numbers in coming years and HMG has been developing core technologies for them.

One of these is the new Electric-Global Modular Platform (E-GMP) which is specifically for BEVs. The E-GMP is ready to be used and from 2021, the E-GMP will support a range of new BEV models. These include the Hyundai IONIQ 5 and Kia’s first dedicated BEV. The platform will be used for as many as 23 BEV models in HMG with the sales target of more than 1 million BEVs worldwide by 2025.

The E-GMP provides various advantages compared to the Group’s existing platforms which have engineering oriented towards internal combustion engines. With a brand new approach that is dedicated to the electrified powertrain, there is increased development flexibility, stronger driving performance, increased driving range, strengthened safety features, and more interior space.

“Today our front-wheel driven Hyundai and Kia BEVs are already among the most efficient ones in their segments,” declared Albert Biermann, President and Head of R&D Division for Hyundai Motor Group. “With our rear-wheel drive E-GMP, we are extending our technological leadership into segments where customers demand excellent driving dynamics and outstanding efficiency.”

*EV variants of the Hyundai Kona (left) and Kia Soul (right) are currently available in some countries.*

Maximizing development flexibility
The E-GMP reduces complexity through modularization and standardization, allowing rapid and flexible development of products which can be used across most vehicle segments. Moreover, flexible development can satisfy various customer needs for varying levels of vehicle performance.

The new platform will also enable the company to enlarge its EV line-up over a relatively short period through modularization and standardization. This will satisfy consumer expectations of variety and choices.

Driving performance and safety
With optimal weight distribution between front and rear, a low centre of gravity thanks to its low-mounted battery pack, and the adoption of electric motors, handling can also be enhanced. A 5-link rear suspension system, which is typically used for medium and large vehicles, and the world’s first integrated drive axle enhance ride comfort and handling stability.

The platform secures battery safety through a battery support structure made of ultra-high strength steel. Hot-stamped steel components surround this structure for additional rigidity. Collision energy can be absorbed efficiently by energy-absorbent sections of the body and chassis, effective energy load paths, and a central section of the battery pack tightly bound to the vehicle body.

The battery pack itself – mounted between the front and rear wheel axles – will be the most power-dense system that HMG has ever created. It has enhanced cooling performance with a new separate cooling block structure which helps make the battery pack more compact. With energy density enhanced by around 10% compared to existing EV battery technology, the battery packs are lighter, can be mounted lower in the body, and liberate more cabin space.

From the early 1980s, the industry moved towards front-wheel drive which offered space-saving benefits. The E-GMP, however, will have rear wheel drive although there can also be all-wheel drive (with an additional electric motor).

Charging System
Most existing EVs and the fast-charging infrastructure provide 50 kWh ~ 150 kWh charging for EVs equipped with a 400V system; however, the development of 800V infrastructure, with up to 350 kWh charging, will gradually enable even more fast-charging.

In line with this trend, Hyundai Motor Group has invested in IONITY, Europe’s leading high-power charging network, as a strategic partner and shareholder. IONITY operates 298 high-power charging (HPC) stations – using a charging capacity of up to 350 kWh – along highways in European countries. The company plans to increase this number to 400 HPC stations by 2022, including 53 currently under construction.

The E-GMP offers 800V charging capability as standard and enables 400V charging, without the need for additional components or adapters. The multi-charging system is a world’s first patented technology which operates the motor and the inverter to boost 400V to 800V for stable charging compatibility.

A BEV using the E-GMP will be capable of a maximum range of over 500 kms with a fully charged battery pack. If the pack is completely empty, it can receive a high-speed recharge up to 80% capacity in 18 minutes; up to 100 kms of driving range can be available with a recharge of just 5 minutes.

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Only electric power for Bentley vehicles by the end of this decade

After over 100 years, the automobile industry is undergoing a major change that will see a progressive diminishing of vehicles with only internal combustion engines, leading to hybrids and eventually only electric powertrains. The global players have already begun the process of making the transition, and Bentley Motors is one of those that has revealed plans which are outlined in its Beyond100 strategy.

Aiming to offer truly sustainable luxury, the carmaker will reinvent every aspect of its business to become an end-to-end carbon neutral organisation as it embarks on its second century. The target is driven by a transformation programme across Bentley’s entire operations and products. This includes switching its model range to offer exclusively plug-in hybrid (PHEVs) or battery electric vehicles (BEVs) by 2026, and full electric vehicles (EVs) only by 2030.

*Bentley’s traditional powertrains with internal combustion engines will be phased out and replaced with hybrid and then all-electric powertrains by the end of this decade.*

No more ICE by 2030
The announcement today highlights Bentley’s plans for another 100 years, evolving from the world’s largest producer of 12-cylinder petrol engines to having no internal combustion engines within a decade.

Bentley’s electrified future was actually previewed with the reveal of the all-electric EXP 100 GT concept car (pictured below) in its centenary year. That concept featured a multitude of sustainable materials. These included 5,000-year-old copper-infused Riverwood, traditionally produced wool carpets and a leather-like textile upholstery made from a by-product of wine-making. Bentley will continue to use only sustainably sourced materials throughout its current, and next generation of cars.

Carbon-neutral production
The Beyond100 strategic plan will see, among other things, the change to a carbon-neutral luxury car factory. Last year, Bentley’s production facility in England became the first luxury automotive factory in the UK to be certified carbon neutral by the Carbon Trust. This followed two decades of implementing innovative solutions, including a water recycling system in the paint shop, local tree planting, installation of a 10,000 solar panel carport, taking the total number of on-site solar panels to 30,000, and a switch to renewable-only electricity sources.

The factory will continue to improve its environmental operations. By the end of 2025, the company intends to reduce its factory environmental impact by focusing on energy consumption, carbon dioxide emissions, wastewater, use of solvents in the paint process and becoming plastic neutral. This will result in a climate positive factory by 2030, actively reducing levels of carbon in the atmosphere, while in parallel the business invests in renewable energy and forestation projects.

Sustainable luxury mobility
Bentley will also redefine its business model which is built around its accelerated journey towards electrification. Having already committed that every model line will be offered with the option of a hybrid variant by 2023, with Bentley’s first pure electric model to be launched in 2025, Bentley is making a clear move towards zero emission mobility.

Achieving sustainable luxury mobility relies heavily on a sustainable business model, and Bentley’s aim is to become the world’s benchmark luxury car business, financially resilient and recession-proof. The challenging economic situation caused by the COVID-19 pandemic resulted in Bentley undertaking its biggest change programme in a century.

This change programme was driving for consistent financial resilience through rapid productivity improvements across the business, and a fundamental restructure. The results from the comprehensive cost and investment structure has placed the business in a position to achieve a positive financial performance for the full year 2020, in spite of the extenuating external circumstances.

Bespoke continues with sustainability
As well as accelerating the product journey towards electrification, Beyond100 opens a new era for Bentley’s bespoke division, Mulliner, which now has a three-portfolio structure comprising Mulliner Classic, Mulliner Collections and Mulliner Coachbuilt. The recently revealed Bacalar signifies the start of this new age as the first member of the Mulliner Coachbuilt family and incorporates elements of the sustainable materials showcased in EXP 100 GT.

The company is committed to handcrafting cars in Crewe for the next 100 years, whilst also preparing for a digital future, and has confirmed it will be investing in two new Research and Development buildings, a vehicle test centre and a dedicated launch quality centre.

“Since 1919, Bentley has defined luxury grand touring. Being at the forefront of progress is part of our DNA – the original Bentley boys were pioneers and leaders. Now, as we look Beyond100, we will continue to lead by reinventing the company and becoming the world’s benchmark luxury car business,” said Adrian Hallmark, Chairman & CEO of Bentley Motors.

The Mulsanne chapter in Bentley history ends

More than 15 million Toyota hybrid vehicles have been sold worldwide

During the 1990s, Toyota launched two models that created new market segments almost overnight. The first was the RAV4, which started the small passenger-car based SUV trend but the second was of great significance. It was the Prius, the pioneer of mass-produced hybrid vehicles.

Today, many carmakers have models with hybrid powertrains too and of the many millions on the roads all over the world, over 15 million have been made by Toyota.

Toyota’s decision to develop hybrid electric vehicles started over 25 years ago when Takeshi Uchiyamada (the company’s Chairman today) led a team to develop a car for the 21st century. Concern for the environment was growing, with momentum coming from the Kyoto Protocol to address climate change, which many nations committed to.

“When we launched Prius, no one even knew what a hybrid was but thanks to early adopters, hybrids have ridden a wave of success into the mainstream,” said Mr. Uchiyamada.

Toyota Prius Gen 1 — *First generation of the Prius*

Toyota focussed on reducing greenhouse gas emissions (specifically carbon dioxide) and other harmful pollutants. With more than 15 million hybrids already in use, Toyota believes that it has made a significant contribution to the environment by reducing carbon dioxide emissions by more than 120 million tonnes worldwide to date (compared to sales of equivalent vehicles with internal combustion petrol engines alone).

The first generation of the Prius was launched in 1997 and in the years that followed, more Toyota (as well as Lexus) models gained hybrid powertrains. There are at least 44 models available globally today.

More than a numerical milestone, the continued and increasing use of hybrid powertrains demonstrates the staying power of the technology. It is a mainstream solution to reduce environmental pollution and also consumption of fossil fuel. This achievement builds on the belief that widespread adoption of more environmentally-friendly vehicles can make a significant positive impact worldwide.

Toyota Hybrid — *Some of the Toyota hybrid models available today.*

Hybrid leads to BEV and FCEV
While Toyota believes that hybrid vehicles are an essential part of the future overall mix of electrified vehicles, two decades of electrification experience also feed into the company’s multi-powertrain strategy. The company does not see a ‘one winner takes all’ scenario but a future where the different electrified technologies – hybrids and plug-in hybrids, fuel cell (FCEV) and battery electric (BEV) vehicles – all play a part.

*Hybrid technology is the core technology which can be used in the development of electric vehicles (EVs), plug-in hybrid vehicles (PHV) fuel cell vehicles. (FCVs)*

As a result of its long hybrid electric vehicle experience, the company has deep transferable expertise in the core electrification technologies which are common across all form of electrified powertrains. Over two decades of continuous development of electric motors, batteries and power control units has taught Toyota how to manage and reuse energy efficiently, providing a range of electrified options for customers.

Toyota hybrid models in Malaysia
UMW Toyota Motor (UMWT) began selling the Prius when it started its third generation in 2009. Due to the heave taxes on CBU (completely built-up) vehicles, the earlier generations were unable to be attractively priced. However, in 2009, the government provided full import and excise duty exemption of hybrid and electric vehicles which made them more affordable.

The move was to demonstrate Malaysia’s commitment to reducing its carbon footprint as well as to help the carmakers introduce hybrid technology to motorists in the country. It was hoped that some companies would then assemble their hybrid models locally.

Toyota Prius — *Third generation of the Prius and Prius c (below) were sold in Malaysia.*

A 4-year period of duty-exemption was given, during which time sales of such vehicles was quite high as their prices were attractive. Besides the Prius, UMWT also imported the smaller Prius c.

Following the withdrawal of the duty-free exemption, the price of the Prius jumped from RM139,900 to RM216,400 while the Prius c which entered the market at RM97,000 rose to around RM153,000. Not surprisingly, sales declined very quickly and imports of the Prius and Prius c ceased. However, Lexus Malaysia continued to offer hybrid variants for its CT, RX and LS models for customers who appreciated the advanced technology.

Four generations of hybrid power and still moving forward with technology

Honda aims to find a ‘second life’ for hybrid/EV battery packs

The lead-acid batteries in motor vehicles have been around for many decades and because they are made from elements that can be recycled, there is an established ‘business’ in collecting and recycling batteries. Even the guy who collects old newspapers will take them as the lead, plastics and even the sulphuric acid can also be recycled.

Lead-acid batteries are therefore considered as ‘closed-loop’ products which means that when their ‘first life’ is over, they can be recycled into other products. It is estimated that globally, 98% of such batteries are being recycled.

With the advent of hybrid and electric vehicles since the late 1990s, more powerful battery packs have appeared. These are needed to store electricity in large amounts and to power the electric motors. These have not continued with the lead-acid approach which would make the battery packs very heavy as they would have to be very big to store sufficient electricity.

Instead, the battery packs for battery-powered electric and hybrid vehicles use nickel-cadmium (NiCd), nickel–metal hydride (Ni-Mh), and more recently, lithium-ion or lithium-ion polymer. The technology is constantly advancing, and the battery packs are getting more compact while their storage capacity keeps growing, making possible longer travel ranges.

Honda Accord Hybrid battery pack — *Battery pack used in an Accord Hybrid.*

End-of-life disposal
The manufacturers have been mindful of the fact that the battery packs have an end-of-life and unlike lead-acid batteries, their disposal is not so straightforward. Various solutions have been explored to keep them in service and Honda Motor Europe, together with SNAM (Societe Nouvelle d’Affinage des Metaux), is investigating the possibility of using batteries in a ’second life’ for the storage of renewable energy in industrial applications.

SNAM is a battery recycling company and is increasing its role in partnership with the carmaker to advance the sustainable usability of its end-of-life battery packs. The pan-European arrangement will see SNAM collect and recycle batteries from Honda’s increasing number of hybrid and electric vehicles and either potentially prepare them for ‘second-life’ renewable energy storage uses or extract valuable materials for recycling if they are not suitable for that purpose.

Honda battery pack recycling — *End-of-life battery packs can be divided in two types – those that can be reconditioned and continue to function as energy storage units or broken apart and their materials recycled (below).*

Honda and SNAM have worked together since 2013 to ensure the traceability of end-of-life batterie packs and dispose of them in accordance with European Union environmental standards. The expansion of this agreement will see SNAM collect lithium-ion and NiMH batteries from Honda’s dealer network and Authorised Treatment Facilities in 22 countries, before analysing how suitable they are for recycling and processing them accordingly.

Second life applications
“As demand for Honda’s expanding range of hybrid and electric cars continues to grow, so does the requirement to manage batteries in the most environmentally-friendly way possible. Recent market developments may allow us to make use of these batteries in a second life application for powering businesses or by using recent improved recycling techniques to recover useful raw materials which can be used as feedstock into the production of new batteries,” said Tom Gardner, Senior Vice-President at Honda Motor Europe.

Safe and low carbon transport is utilised for the collection of used batterie packs. On arrival, SNAM assesses which battery packs are valid for inclusion in a new energy storage device. These are then repurposed and made available by SNAM for domestic and industrial applications.

When battery cells are damaged and unsuitable for ‘second life’ applications, materials such as cobalt and lithium can be extracted using hydrometallurgy techniques involving the use of aqueous chemistry. These can be reused in the production of new batteries, colour pigments or as useful additives for mortar. Other commonly used materials including copper, metal and plastics are recycled and offered to the market for use in the production of a variety of applications.

Honda e starts Honda’s electrification strategy in Europe

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