Electric Vehicles Archives

GM looking forward to all-electric future with Ultium batteries

Like many carmakers, General Motors is heading for an all-electric future and putting considerable resources into building a multi-brand, multi-segment EV strategy with economies of scale that can rival its full-size truck business. By right, the company should be way ahead in the EV field today, having come out with the first mass-produced all-electric car, the EV-1, in 1996.

However, advanced as it was, the car was expensive to produce, and GM saw the EV segment then as being unprofitable, so it stopped making the car. Developing EVs then was not a priority (engineers who were assigned to such projects considered them ‘dead-end jobs’) and so GM didn’t advance its EV technology the way Toyota had done so with its hybrid technology after it introduced the Prius in the late 1990s.

GM EV-1 — *In 1996, GM launched the first mass-produced EV known as the EV-1. But it saw the EV segment as unprofitable and did not carry on development and marketing.*

Now GM is accelerating its R&D into EV technology and the heart of its strategy is a modular propulsion system and a highly flexible, third-generation global EV platform powered by proprietary Ultium batteries.

“Thousands of GM scientists, engineers and designers are working to execute a historic reinvention of the company,” said GM President Mark Reuss. “They are on the cusp of delivering a profitable EV business that can satisfy millions of customers.”

The Ultium batteries and Propulsion System
GM’s new Ultium batteries are unique in the industry because the large-format, pouch-style cells can be stacked vertically or horizontally inside the battery pack. This allows engineers to optimize battery energy storage and layout for each vehicle design.

Ultium energy options range from 50 to 200 kWh, which could enable a GM-estimated range up to 640 kms or more on a full charge with 0 to 100 km/h acceleration as low as around 3 seconds. Motors designed in-house will support front-wheel drive, rear-wheel drive, all-wheel drive and even performance all-wheel drive applications.

Ultium-powered EVs are designed for Level 2 and DC fast charging. Most will have 400-volt battery packs and up to 200 kW fast-charging capability while the truck platform will have 800-volt battery packs and 350 kW fast-charging capability.

Driving costs downwards
The flexible, modular approach to EV development is expected to drive significant economies of scale for lower production costs and create new revenue opportunities. The cells use a proprietary low cobalt chemistry and ongoing technological and manufacturing breakthroughs will drive costs even lower. Together with LG Chem, its joint venture partner, GM sees continuous improvement in battery costs as they are driven down to US$100/kWh.

GM’s all-new global platform will be flexible enough to build a wide range of trucks, SUVs, crossovers, cars and commercial vehicles. To build them with capital efficiency, GM will leverage on existing properties, including land, buildings, tools and production equipment such as body shops and paint shops.

The vehicle and propulsion systems are designed together to minimize complexity and part counts beyond today’s EVs, which are less complex than conventional vehicles powered by internal combustion engines. For example, GM plans 19 different battery and drive unit configurations initially, compared with 550 internal combustion powertrain combinations available today.

Third-party forecasters expect EV volumes in the US market to more than double from 2025 to 2030 to about 3 million units on average. But GM believes the numbers could be materially higher as more EVs are launched in popular segments, charging networks grow and the total cost of ownership to consumers continues to fall.

The Hummer is returning but you’ll hardly hear it coming… (w/VIDEO)

Volkswagen’s electric vehicles will use a 1-speed gearbox!

Volkswagen’s modular electric drive matrix (MEB) platform is to be the key element in its future models as electrification increases. The platform, to be used by Volkswagen Group brands such as Audi, SEAT, Skoda and Volkswagen, has many sophisticated components optimized for electric drive systems.

One of these is the APP310 e-drive unit that will used for the Volkswagen ID.3 due in showrooms from mid-2020. The powerful unit transmits power to the driven wheels using an extremely compact gearbox with a single gear. The mechanism used has only a small number of cogs. It is manufactured by a Volkswagen subsidiary.

Is one gear enough?
But why is a single gear enough for the drive motor? The traction, ie the force that allows movement, and speed of a motor vehicle depend on the rotational speed of its drive system. As the speed of the drive system increases, the force transmitted to the wheels – the torque – can vary.

With a vehicle with a combustion engine, the torque increases along with the engine speed and then falls again. With an electric drive system, however, the maximum torque is available immediately and remains constant over a wide range of speeds. The use of a multi-speed gearbox to achieve the desired speed or the necessary torque along the speed curve is therefore not absolutely necessary.

One gear for every situation
That is why a 2-stage 1-speed gearbox is practical for the Volkswagen ID.3. When reversing the car, the direction of the electric drive system is simply reversed. In addition to various other components, power electronics are responsible for this and for the power characteristics of the drive system.

Volkswagen e-drive — *The e-drive weighs just 90 kgs and is compact enough to fit inside a bag.*

In order to generate the maximum output of 150 kW, the 90-kg electric drive unit must rotate at high speeds. For a high level of torque, a 10x transmission ratio is used. To save space, the gearbox has a two-stage design with two smaller cogs instead of one big one. As a result, the electric drive motor in the ID.3 provides maximum torque of 310 Nm constantly over a wide range of speeds. The maximum speed of 160 km/h is reached at a maximum of 16,000 rpm.

Precision manufacturing
Because an electric drive system is very quiet, the level of noise in an EV is very important. Even the tiniest sources of noise can be heard. The parts for the 1-speed gearbox must therefore be manufactured with great precision to ensure that they do not cause any additional noise. At the end of the production line, not only the power characteristics of the electric drive system checked but so are the relevant noise levels.

2020 Volkswagen ID.3 makes global debut

Volkswagen tries a new approach to recharging EVs in carparks (w/VIDEO)

As the electric car era approaches, it’s not just new types of vehicles that are needed but also supporting services, especially to recharge the battery packs. Unlike the petrol station network which is the product of many decades and has global coverage, battery recharging points and stations are only just beginning to be set up.

For companies that invest in recharging stations, there is a need to ensure sufficient demand and usage so as to get returns on their investment. That time is coming as the population of EVs (and also plug-in hybrids) rises and more vehicles need to be recharged daily.

Volkswagen is also exploring other approaches and has provided a glimpse into the future in which the search for charging stations becomes unnecessary. Instead, mobile charging robots will take over this task, going to the vehicle completely autonomously. After it is started via app or V2X communication, the mobile robot drives itself to the vehicle that needs charging and communicates with it.

Everything done autonomously
From opening the charging socket flap to connecting the plug to decoupling, the entire charging process occurs without any human interaction. The robot brings a trailer in the form of a mobile energy storage device to the vehicle and connects it. It then uses this energy storage device to charge the battery of the electric vehicle. The mobile energy storage device stays with the vehicle during the whole charging process. The robot, in the meantime, charges other electric vehicles. Once the charging service is complete, the robot collects the energy storage device and brings it back to the charging station.

“The mobile charging robot will spark a revolution when it comes to charging in different parking facilities, such as multistorey car parks, parking spaces and underground car parks because we bring the charging infrastructure to the car and not the other way around. With this, we are making almost every car park electric, without any complex individual infrastructural measures,” explained Mark Moller, Head of Development at Volkswagen Group Components. “It’s a visionary prototype, which can be made into reality quite quickly, if the general conditions are right,” he added.

Volkswagen Group Components is researching different approaches to the assembly of charging infrastructure and has already developed several successful products. The flexible quick charging station and DC wall boxes are already part of a future charging family. Customer-oriented, intelligent and flexible approaches to charging are at the centre of the research. Other innovative products such as the charging robot are currently being developed.

Autonomous, compact and flexible
The prototype consists of a compact, self-driving robot as well as flexible and agile energy storage devices, also known as ‘battery wagons’. When fully charged, these are equipped with an energy content of around 25 kWh each. A charging robot can move several battery wagons at the same time. With its integrated charging electronics, the energy storage device allows for DC quick charging with up to 50 kW on the vehicle.

The robot, which can move autonomously, is fitted with cameras, laser scanners and ultrasonic sensors. The combination of these systems not only allows the robot to carry out the charging process completely autonomously but also to move around freely in the parking area, recognising possible obstacles and to react to them appropriately. Depending on the size of the parking area or the underground carpark, several charging robots can be employed simultaneously so that several vehicles can be attended to.

The mobile charging robot can be put to use in various ways. It isn’t just a robot arm that connects a car to a fixed charging station. Instead, drivers have the choice to park in any available space, independent of whether a charging station is free or not. The robot brings the charging station in the form of a mobile energy storage device directly to the vehicle.

For operators of different parking facilities this is a quick and easy solution to electrify every parking space. “This approach has an enormous economic potential,” said Moller. “The constructional work as well as the costs for the assembly of the charging infrastructure can be reduced considerably through the use of the robots.”

The compact design of the charging robot is perfectly suited for use in restricted parking areas without charging infrastructures, such as underground carparks. Even the well-known problem of a charging station being blocked by another vehicle will no longer exist with this concept.

VW ID.Charger — *Owners can also install the ID. Charger, a unit developed by Volkswagen, in their homes.*

36,000 places to recharge by 2025
The project is among Volkswagen’s initiatives to establish a charging infrastructure at many levels. Together with its dealers, the company aims to install a total of 36,000 charging points throughout Europe by 2025. A large proportion of these will be in public areas.

Volkswagen is also launching its own wallbox for home charging called the ID. Charger. And as a co-founder of the IONITY joint venture, Volkswagen participates in installing 400 fast-charging parks on major European highways. Medium-term, charging an EV is to become as easy as charging a smartphone.

Volkswagen owners can get more with VIP

Electric vehicles are far from boring these days and you can even drift with them (w/VIDEO)

Although Formula E has shown that electric power can be used for racing cars and the appearance of fully electric vehicles (EVs) in some motorsports events has also proven that all-electric powertrains can be very powerful, there are still people who imagine EVs are slow and boring.

Such vehicles were first promoted for their clean technology as they generated no exhaust gases while in use, meaning zero emissions into the environment. They are ideal for personal mobility as well as various forms of transport within cities or even for inter-city travel.

With the current state of EV technology, the range on a fully-charged battery pack has been steadily increasing and so has performance. As it is, the characteristic of an electric motor is that it generates maximum torque virtually from standstill, zipping off the line like a radio-control models car when the accelerator pedal is depressed.

Drifting and electric mobility
And believe it or not, you can also drift an EV, as a professional stunt driver shows with the latest Nissan LEAF. Drifting is usually performed by sportscars with powerful internal combustion engines, but Nissan wanted to try something different. In an unlikely pairing of adrenaline-inducing drifts and electric mobility, the LEAF was shown to produce both maximum torque and force, while delivering virtually silent donuts and burnouts.

The world’s best-selling EV therefore debunked outdated perceptions that electric vehicles are nothing but large golf carts. Throughout the test, the LEAF’s emissions naturally remained at zero – a number symbolized by the vehicle’s donut tread marks.

Try the LEAF yourself
You don’t have to buy a LEAF just to go drifting. Buy it for the driving pleasure that comes from much quieter and smoother motoring, and the satisfaction of doing your part to protect the environment for future generations. And you no longer have petrol costs to worry about too!

The LEAF is available in Malaysia and to locate a showroom where you can learn more about it and take a test-drive, visit www.nissan.com.my.

FIRST DRIVE: 2019 Nissan Leaf – “Simply Electrifying”

Hans Zimmer to create e-sounds for BMW Group vehicles

For decades, engineers have worked hard to bring down noise levels in cars because noise can cause fatigue and if a car is quiet, it is considered as being refined. They still have to work at lowering noise as well as vibrations and harshness (NVH in industry-speak) but with the advent of electrically-powered vehicles, ‘sound’ will be viewed differently.

On the one hand, for safety reasons, governments are asking manufacturers to install devices which can emit sounds to warn pedestrians and other road-users of the electric vehicles approaching them. Since 2009, with the introduction of the MINI E test fleet, acoustic engineers from the BMW Group were already working on artificially generated sound, which was intended to contribute to the better perceptibility of vehicles with much quieter drivetrains. Since the launch of the BMW i3, customers have been able to choose acoustic pedestrian protection as optional equipment.

BMW i3 — *In crowded urban areas with a lot of pedestrians, the quientness of electric cars means that some warning sound is needed as they move around.*

Continued development of warning sounds
The sound of the acoustic pedestrian protection has since been further developed in line with new legislative requirements and is now gradually being rolled out as standard in all plug-in hybrids and all-electric vehicles from BMW (where required by law). The aim in the development has been to provide the important warning function without disturbing pedestrians.

Now the BMW Group is looking at e-sound for its future electric vehicles and have partnered Hans Zimmer, a noted composer for Hollywood movies, to further develop BMW IconicSounds Electric. The move follows an earlier collaboration which saw Zimmer and BMW Sound Designer Renzo Vitale present their jointly developed e-sound for the BMW Vision M NEXT.

“We have the unique opportunity to turn electric driving in a BMW into a magnificent experience with outstanding sonority. I am really looking forward to the challenge of shaping the sound for future electric BMW’s. Developing the sounds for the BMW Vision M NEXT together with Renzo Vitale was already an inspiring, new experience for me,” said Zimmer.

In production models from 2020
The most recent co-creation is the sound signalling readiness for driving in purely electric and plug-in hybrid vehicles. This unique sound will be heard in production models of the BMW brand next year. “Sound Design gives us the opportunity to evoke positive emotions in our vehicles. This new start-sound triggers joyful anticipation of the electric drive, when the customer enters his vehicle and presses the Start/Stop button,” explained Vitale.

The silence of driving electrically is often cited as a major advantage of electric mobility. However, as the range of electrified models increases, a gap in the emotionality of the driving experience arises for the driver. Under the brand name “BMW IconicSounds Electric”, a visionary sound offer will be created for future electrified vehicles from BMW.

Enhancement to driving pleasure
“Over the years, the sound of our vehicles has enthused and accompanied millions of people. We are very excited about the exceptional chance of creating the sounds for BMW’s electric mobility together with Hans Zimmer. Thereby we can charge future emotions of our customers worldwide anew and redefine sheer driving pleasure,” said Stefan Ponikva, Vice-President BMW Brand Experience.

As composer and curator of BMW IconicSounds Electric, Zimmer will contribute his expertise to various projects for sound creation for electrified BMW vehicles worldwide. The variety of projects may include sounds for vision vehicles and concepts, production models, composition of sound signs, as well as sound creation for communicative occasions focusing on the acoustic-emotional character of electric mobility.

PETRONAS Holds Inaugural EV Fluids Symposium In Italy

PETRONAS Lubricants International (PLI), the global lubricants manufacturing and marketing arm of PETRONAS, recently organized the inaugural Electric Vehicle (EV) Fluids Symposium at its Global Research and Technology (R&T) Centre in Turin, Italy.

“The EV Fluids Symposium is our next initiative to work together, deliberate possibilities
and set a shared agenda towards a cleaner future.”
PLI Managing Director and Group CEO, Giuseppe D’Arrigo.

Giuseppe D'Arrigo, PLI CEO — *Giuseppe D’Arrigo, PLI Managing Director & Group CEO*

Attended by more than 120 participants, the one-day event drew industry-leading experts from across the world to discuss and feature EV innovations that support a cleaner, energy-efficient and more sustainable e-mobility future. It provides a platform for these experts to share future EV technology trends, their market relevance and the role of fluids in the evolution of e-transmission and battery technologies.

In addition, the EV Fluids Symposium aimed to encourage discussions on managing the climate challenge by harnessing EV technological developments and operational discipline.

*Datò Sri Syed Zainal, Vice-President Downstream Marketing PETRONAS and Chairman of PLI, also spoke at the symposium.*

“At PLI, we’ve pledged to double our investments and dedicate 75% of our R&T expenditure in projects that contribute to reducing CO₂ emissions. PLI’s venture into the EV market that was announced earlier this year through PETRONAS iona range of e-fluids reinforces our commitment to the development and deployment of fluid technology. The EV Fluids Symposium is our next initiative to work together, deliberate possibilities and set a shared agenda towards a cleaner future,” said PLI Managing Director and Group CEO, Giuseppe D’Arrigo.

During the symposium, PLI also shared the findings of the industry’s first global study in EV Technology and Fluids focusing on Electric Drive Units and Batteries. The study, carried out in collaboration with FEV Consulting, concluded that innovation is crucial in advancing EV performance and durability, and continued improvement is needed to promote increased adoption rates of electric transportation by consumers.

Mercedes-Benz EQC — Although EVs may not have internal combustion engines requiring lubrication and protection, the electric powertrains still require various fluids to optimise performance and efficiency. For this reason, PETRONAS has developed a new generation of e-fluids for electric vehicles.

Commenting on the state of the industry, Electric Vehicle Outlook Founder & Event Host, Roger Atkins said: “Change is a challenge, and with the rapid integration of electric vehicles into the global mobility eco-system, that challenge is being met with unprecedented and active collaboration between manufacturers, academia, and the world’s smartest engineering teams. I am encouraged to see the focus and ambition here at the EV Fluids Symposium. The twin imperatives of climate change and air quality can only be tackled by truly maximizing the efficiency of our planet’s mobility machines, amongst others.”

At the PETRONAS Global R&T Centre, attendees had the opportunity to tour the product development laboratory and mechanical testing facilities to understand the experimental work that goes into developing PETRONAS e-fluids.

PETRONAS Global R&T Centre lab tour_2 — *Attendees touring the PETRONAS Global R&T Central lab.*

Since the introduction of PETRONAS Carbon Commitments in 2012, the company has decreased its monitored carbon footprint by 13% from 2017, which is a cumulative 12 million tonnes of greenhouse gas emissions reduction. PETRONAS is also collaborating with Daimler Automotive in green projects towards low-carbon fuel and vehicle emissions control.

More recently, the efforts of Malaysian national oil corporation towards a sustainable future included the establishment of PETRONAS Carbon Commitments Guidelines and a New Energy unit to enhance capabilities in the renewables sphere.

Click here to read other news and articles on PETRONAS products and activities.

Visit www.mymesra.com.my to know more about PETRONAS products and services in Malaysia.

Circontrol starts tapping into growing PHEV/EV market in Malaysia with aftermarket charging stations

With the introduction of more plug-in hybrid electric vehicles (PHEVs) in Malaysia in coming years, along with a few all-electric models, it’s clear that there will be a market for recharging facilities. For now, such units are being offered by the companies selling the PHEVs or EVs, usually as part of a package with the purchase of the car.

No company will be allowed to have a monopoly of the sale of such recharging facilities otherwise the powerful Competition Commission will take action. This means that there are opportunities for companies specialising in such products to start offering them in Malaysia.

*Nissan LEAF – one of the EVs available in Malaysia*

One of them is Circontrol, a 22-year old Spanish company which has a range of chargers for private and commercial application. The company has deployed over 55,000 charging points across 60 countries since they’ve started and also work with brands like Nissan, Audi and Volkswagen on providing Original Equipment for their PHEVs and EVs.

For homes, Circontrol offers their Wallbox eHome and Wallbox eNext. Protected by an ABS plastic housing that’s UV-resistant for longevity. The unit re also IP54-protected, meaning they are partially protected from dust and sprays or splashes of water.

Some of their charging stations like the eVolve Smart and eNext Elite can be connected via ethernet port or 3G/GPRS to make management much easier. They have 7.4kw power supply and are priced at RM5,300 (including installation with additional charges if the location is outside the Klang Valley).

For those who need quick charging solutions, there are DC Chargers like the Raption 50 which can ‘refill’ battery packs within half an hour, it is claimed. These Fast Charging stations feature modular power technology and power scalability to keep them cost-effective and relevant to future advances in EV battery technology.

Designed to be installed in both public access environments (urban spaces, shopping centres, hotels, airports, R&R areas, etc) or company properties where vehicles need to be ready to continue their journey, the Raption 50 is designed to meet the most important market demands. With its state-of-the-art modular power technology allows a bigger uptime, increases availability and flexibility. Another key attribute is its sophisticated, slim and robust design that makes Raption 50 and ideal EV charger for any type of location, from stylish urban areas to industrial sites.

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Kia’s ‘Electric Mission’ gains insights into the electrification of personal transport in Europe

Following a 4,100-km drive through the world’s most developed electrified car markets, Kia Motors collected data that provides insights into the major trends for electrification in Europe. Referred to as the ‘Electric Mission’, the project was carried out in partnership with automotive research consultancy World Shopper.

The Electric Mission lasted 10 days, with a team of researchers visiting towns and cities across Northern Europe that are shaping the future of electric mobility. The team completed the journey in a Kia e-Niro all-electric crossover, passing through Germany, the Netherlands, Denmark, Sweden and Norway.

During the road trip, World Shopper’s industry analysts met with more than a hundred decision-makers and stakeholders in the world of vehicle electrification, gathering data and first-hand insights for the Electric Mission report. The researchers also met with consumers, exploring attitudes towards electric vehicles, charging infrastructure, trends for electric vehicle adoption, and how they integrate electric vehicles into their daily lives.

The report suggests that consumers are still put off by the perception of high electric vehicle purchase costs, inadequate vehicle charging infrastructure, and long charging times. Crucially, the report also shows how drivers have successfully switched from petrol and diesel vehicles and incorporated electric vehicles into their lifestyle.

Home charger makes a difference
The report found that consumers can more easily make the transition from fossil fuels to electric power by installing a home charging point. Often subsidised, or offered with the purchase of the electric car, home chargers enable drivers to leave home every morning with a full battery – not a luxury enjoyed by drivers of conventional vehicles.

Owners of the e-Niro, for example, can set off every day with the maximum 455-km range when the battery pack is fully charged – a range significantly further than most drivers cover in a single day. The report found that the average single drive would only require around 4kW of the e-Niro’s 64 kWh battery capacity.

Adapting ‘refuelling’ habits
While the research from Kia and World Shopper highlighted a shift towards charging vehicles at home or at the office, many people have also fit electric vehicles into their lives by adapting their day-to-day charging habits. In Norway, for example, many drivers use vehicle recharging time to have something to eat, have a coffee, or catch up on their email.

The proliferation of fast chargers at service stops on major roads enables drivers to quickly recharge their vehicles sufficiently for a week of commuter driving in the space just 30 minutes. For example, charging a vehicle with a battery pack of 50kWh using a 175 kW fast charger, a driver can recover an 80% battery charge in between 15 and 30 minutes.

Sharing the experiences of others
Kia found during its research that one of the easiest ways for buyers of fossil fuel vehicles to overcome any concerns around electric vehicles was hearing about positive experiences of their friends and family. With vehicles such as the e-Niro making long-distance, zero-emissions transport possible, many drivers just need to hear about the added benefit of lower running costs, maintenance costs and lower vehicle taxes to be convinced. Word-of-mouth remains the number one reason why many people have switched to electric power in certain markets, and the longer driving range of the new generation of electric vehicles is now making them a truly viable choice for the majority of drivers.

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Explosions that prevent electric shocks in electric vehicles after accidents

Explosions are normally associated with something negative or bad as they generate a lot of energy which can be damaging. However, there are also some explosions which can save lives – these are tiny explosions which reduce the risk of electric shocks after a vehicle has an accident.

With more and more electric cars on the road, many drivers are increasingly uncertain what they should do or not do in the event of a collision. Electric motors also present rescue crews with new challenges. In fact, like any other vehicle, electric vehicles are equipped with safety features for such events.

Deactivating electrical circuits right away
For example, Bosch semiconductors help prevent the risk of electric shock after an accident. Specially designed microchips deactivate the vehicle’s power circuits in a fraction of a second. This enables rescue crews to set to work immediately and ensures that first responders and the vehicle’s occupants remain safe.

“Our semiconductor technology plays a vital role in the safety of hybrid and electric vehicles,” said Jens Fabrowsky, Member of the executive management of Bosch’s Automotive Electronics division. Bosch supplies vehicle manufacturers with semiconductor chips for incorporation in special systems that safely disconnect the battery in the event of a collision.

“Faced with the growing number of electric vehicles that could potentially be involved in collisions, such systems are absolutely essential if we are to fulfil our mission of helping and rescuing victims of road accidents as rapidly and safely as possible,” added Karl-Heinz Knorr, Vice-President of the German firefighters association.

Higher voltage than home electrical outlets
For a lot of people, damaged cables as the result of an accident are a cause for concern: the current from the battery pack could leak into the metal bodywork of a hybrid or all-electric car. After all, these batteries are designed to deliver a voltage of 400 to 800 volts (the voltage from your home electrical outlet is 240 volts and that’s already dangerous). But they can rest assured because Bosch semiconductor chips ensure that the high-voltage battery is automatically disconnected, so that nobody at the scene of the accident – vehicle occupants, rescue crews, first responders – comes into contact with current-carrying components.

Mercedes-Benz A-Class PHEV — *New models like the Mercedes-Benz A-Class Plug-In Hybrid variant have a lot of high-voltage cables and systems which must be shut down to avoid causing harm to rescuers.*

The semiconductor devices are part of a pyrotechnical safety switch system, or pyrofuse. These systems ‘blow out’ whole sections of the cable connection to the high-voltage battery by means of miniature explosive charges, thus quickly and effectively shutting off the power circulation. Bosch semiconductors play a decisive role in these systems. If, for example, the airbag sensor detects an impact, the tiny devices – measuring no more than ten by ten millimetres and weighing just a few grams – trigger the pyrofuse. This sets off little explosions that drive a wedge into the high-voltage cable between the battery unit and the power electronics, disconnecting the two. By cutting off the flow of current this way, the risk of electric shock or fire is eliminated.

Reliability in millions of applications
The CG912 integrated airbag system IC used in the pyrofuse system is an application-specific integrated circuit or ASIC. The specific application in this case is automotive safety. “Our ASICs, which are no bigger than a fingernail and yet populated with millions of transistors, are custom-designed to activate safety functions reliably within a fraction of a second,” Fabrowsky said.

Originally developed by Bosch to trigger the release of airbags, the CG912 has performed reliably millions of times in this application. Modern vehicles contain dozens of ICs to control not only safety features such as airbags and belt tensioners but also cruise control, distance sensors, high-beam assist, lane-keeping support, rain sensors, and driver drowsiness detection. “Nowadays, there is hardly any area of automotive engineering that does not involve the use of microchips,” he noted.

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Tata Motors to launch EV models with ZIPTRON technology developed in-house

Tata Motors will soon offer EVs (electric vehicles) with its own state-of-the-art technology which will be launched during 2020. Known as ‘ZIPTRON’, the EV powertrain technology is a building block towards the Indian carmaker’s strive for commonality so as to drive economies of scale. Pursuing this strategy will help to make new technologies affordable for Indian consumers.

While full details have not been released, the new technology embodies important characteristics such as an efficient high voltage system, zippy performance, long range, fast charging capability, a battery pack with warranty of 8 years, and adherence to IP67 standard which relates to protection from water.

In-house development
Speaking at the announcement recently, Guenter Butschek, CEO & MD of Tata Motors said: “We are proud to present this state-of-art technology brand – ZIPTRON – which has been designed in-house while utilizing our global engineering network. At the heart of our future EV line-up, this technology will deliver a thrilling driving experience to our customers aspiring to go-green. Rigorously tested across 1 million kms, ZIPTRON technology is well proven, advanced and reliable. With this technology, we hope to usher in a new wave of eMobility in India and accelerate faster adoption of EVs, supporting the government’s vision.”

Tata Motors ZIPTRON — *ZIPTRON battery pack*

The ZIPTRON powertrain has a highly efficient permanent magnet AC motor providing superior performance on demand. It is claimed to have best-in-industry protection against dust and water, an important requirement for Indian motoring conditions. Furthermore, ZIPTRON technology has smart regenerative braking to charge the battery while on the drive, enhancing the range.

Tata Motors EV — The Tata Motors’ Electric Vehicle Business Unit has also been supporting the IIT Bombay Racing Team for the past 4 years as a key sponsor to help a team of 70 budding engineers fulfill their aspirations of developing an electrically-powered racing car.

In the coming months, Tata Motors will be starting a campaign to introduce ZIPTRON technology as well as educate consumers on EVs.

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