Researchers at Germany’s esteemed Fraunhofer research organization have developed a casting technique to produce lightweight aluminum windings with a higher groove fill factor than conventional copper wire. The coils are composed of cast aluminum, and are based on a flat conductor arrangement, which leads to a higher slot fill factor and thus better use of… Read more »
Researchers at Germany’s Fraunhofer Institute for Material and Beam Technology IWS have developed a new battery cell production process that coats electrodes with a dry film instead of liquid chemicals. This simplified process saves energy and eliminates toxic solvents. The Fraunhofer researchers, with colleagues from Samsung, describe their findings in a new paper, “Overcoming binder… Read more »
Researchers from the Fraunhofer Institute have integrated current and temperature sensors, 600 V-class power transistors, freewheeling diodes, and gate drivers onto a gallium nitride (GaN)-based semiconductor chip. The new circuit measures 4 x 3 mm and enables high switching frequencies and a high power density, while providing fast and accurate condition monitoring, according to the… Read more »
The Fraunhofer Institute and Hitachi Metals say they’ve produced an on-board charger (OBC) prototype that delivers both high power output and compactness by using soft magnetic materials developed by Hitachi. Hitachi says the technology enables the OBC prototype to generate a power density of 3.8 kW/l. Hitachi explains that there is typically a trade-off between… Read more »
Researchers from the Fraunhofer Institute for Chemical Technology and the Karlsruhe Institute of Technology have developed a new method for cooling electric motors, which could help reduce the weight of EVs. With the new cooling method, motors can be housed in lighter-weight polymer materials, and they also benefit from increased efficiency and power density. The… Read more »
Under a project sponsored by the German Ministry for Economic Affairs and Energy, Daimler and the Fraunhofer Institute, together with German conglomerate thyssenkrupp and engineering firm IAV, are co-developing the design and production of bipolar batteries. Bipolar batteries are still in the laboratory stage and have not moved past pilot scale. The project, named EMBATT-goes-FAB,… Read more »
Germany’s Fraunhofer Institute for Applied Solid State Physics has demonstrated what it calls the world’s first monolithically integrated GaN half bridge for the 600 volt class. Half bridge circuits are the centerpiece of many voltage converters. Monolithic integration combines several components on a single GaN chip, enabling small, powerful systems to be created. Monolithically integrated… Read more »
Finland-based Outokumpu is working on lightweight stainless steel solutions for EVs in cooperation with Germany’s Fraunhofer Institute. Their latest innovation is a new battery pack that combines several lightweight engineering technologies as well as new types of cooling and structural strategies. Because EV batteries are mainly installed in the underfloor area, their casings have high… Read more »
Researchers at Germany’s Fraunhofer Institute have developed a modular battery system that could offer lower cost and improved range by making it easier to replace defective cells. In theory, all the individual cells of a battery can store the same amount of energy. In practice however, their capacities vary, and because the cells are connected… Read more »
Unlike an ICE vehicle, which produces more than enough engine heat to warm the interior, an EV requires an additional electric heater, which gobbles power and limits range. In a worst-case scenario on a cold winter day, the car’s effective range could be cut in half. Several groups around the world are looking for a… Read more »