E- Mobility Stage Agenda

This session will set the scene on global trends that are shaping the e-mobility sector in 2023 as well as looking ahead to how regulatory and economical movements are likely to further have an impact. With the world focusing on reducing carbon emissions, each country and region is managing this in a different way, all impacting initiatives from the OEMs. To ensure you keep ahead of the curve on the most recent updates, this session is a must attend. Global examples of new legislation that will be covered in this session include:  

• Europe- Reduction of the average Co2 emission level by 15% in 2025
• China’s new Energy Vehicles (NEV) mandate
• India Faster Adoption and Manufacturing of Electric Vehicles (FAME II)
• Japan goal to have all new passenger cars electrified mid 2030 (Ministry of Economy, Trade and Industry (METI)

The Transformation Hub “ScaleUp eDrive” is a research project funded by the Federal Ministry for Economic Affairs and Climate Action of Germany (BMWK). This project has a total volume of more than 4.8M€ and prepares current trend and industry information and makes it accessible to all players in the value chain of the electric drive train in Germany. In this way, it contributes to securing value creation and employment of manufacturing companies, especially SMEs, in the field of plant engineering and the production of electric drives and their components in Germany.

The project consortium consists of the five partners, e-mobil BW GmbH, Bayern Innovativ, the German Aerospace Center (DLR), the FTM of the technical University of Munich as well as the PEM of the RWTH Aachen University. “ScaleUp eDrive” is a growing platform open to all interested parties from within the industry as well as companies looking to join this market.

This session will discuss this project in more detail, highlighting the benefits it brings to the sector and key findings to date. Our speakers will highlight what to expect moving forward and the key timelines and outcomes they are working towards.

What are the main challenges of the Afid for the industry and what is the impact? This session will look at these roll out plans in more detail and evaluate the challenges and opportunities, learning from countries and case studies around the globe.  

Electrical steel (ES) is a core component in traction motors for electrified vehicles; improving the functional magnetic and mechanical properties. ES is key to improving the traction motor efficiency and the total vehicle energy consumption. Increased electric motor efficiency subsequently reduces the CO2 emissions during the in-use phase of the electric vehicle. This session will delve deeper into how ES is succeeding in reducing the carbon footprint for electric vehicles with real world examples.

Due to a continued concern on the external dependence of permanent magnets in Europe, induction technology is being pushed beyond its limits to maximise performance.

• With novel materials, material characterisation and multi-domain design, power-speed capability of laminated rotor induction motors can match that typically associated with surface permanent magnet machines, at a fraction of the cost.
• This session will review the findings relating to lower cost induction motors, highlighting how they can successfully be used as an alternative to permanent magnets.

Emachine technologies have significantly improved the manufacturing process of electrical machines by enhancing their performance, efficiency, and reliability. This session will cover the major advancements relating to the  use of Emachine technologies, benefits and contribution to the development of more energy-efficient electrical machines. Topics to be discussed include:

• Manufacturing process improvement
• Cost- effective process more efficient
• Emachine winding technologies enable manufacturers to use a variety of materials

eD-MOIA is a multi-disciplinary optimization methodology whose objective is to find the optimal design of the electric powertrain. The tool ensures that the optimal powertrain respects the constraints imposed by the complete system. 

During this session the eDrivetrain will be presented including: 

• systemic optimization approach 

• examples of the models used 

• study case showing the impact of the decisional model on the resulting optimal powertrain solution 

Magnet wire is used to wind the stator in electric motors and transformers, and its properties can significantly affect the performance of the system. The use of PEEK in the manufacturing of magnet wire has several advantages over other materials.  This presentation is covering the benefits and usage of PEEK including:

• Electrical properties and high temperature resistance
• Chemical resistance and friction coefficient
• Performance improvement

Interior Permanent Magnet (IPM) motors are widely used in industrial applications because of their high efficiency, high power density, and good dynamic performance. IPM rotor magnetization technologies play a critical role in the performance and reliability of these motors.

The evaluation of IPM rotor magnetization is critical to ensure the performance and reliability of the motor. The selection of the magnetization method and the evaluation methods should be based on the specific characteristics and operating requirements of the motor. During the session different methods for measuring the magnetic flux density will be proposed and we will explore key magnetization characteristics. Evaluation methods used to assess the performance and quality of IPM rotor magnetization will also be discussed.

Laser processing tools have become increasingly important in the manufacturing of components for e-mobility applications. As the demand for electric vehicles and related products continues to grow, the need for high-quality and efficient production methods becomes more important.

Adapted laser processing tools offer a promising approach to the manufacturing of e-mobility components, as they can improve precision, speed, and flexibility, while reducing costs and improving production efficiency. This session will cover the following:

• Several factors to be considered, including the materials being processed
• Geometries required, and the production volumes
• Specialized training and expertise are required to operate and maintain these tools, which can be more complex than traditional manufacturing methods

The use of thermally conductive polyurethane encapsulants processed by an injection process is particularly beneficial for battery cells in electric vehicles and other high-power applications.

Description of the requirements of the battery application and the related processing requirements will be covered in this session.

• Comparison of different technologies and materials
• Thermal conductivity and efficiently transfer heat away from the battery cells
• Chemical resistance and flexibility
• Durability, high mechanical strength, and resistance to abrasion

Designing the best winding wire e-mobility specification involves considering a number of factors that impact the performance and reliability of the motor or generator. During this session key aspects that impact the winding wire selection will be covered including: 

• Operating environment impact 

• Electrical and mechanical properties 

• Material selection and production requirements 

• Industry standards and cost considerations 

Copper welding with electron beam technology offers numerous benefits. The process involves using a high- energy electron beam to melt the copper surfaces to be welded, creating a strong bond between the two pieces of metal.

This session will explore the key advantages of electron beam welding for copper:

• Reduce production time and increase efficiency
• Reduce the risks of distortion, cracking and other heat related damage to the copper components
• Due to the mentioned advantages and opportunities electron beam is the perfect welding tool for E-Mobility. The electron beam allows to shift boundaries and to create new solutions for E- Mobility

Fuel Cell Electric Vehicles (FCEVs) are one of the promising alternatives to traditional internal combustion engine vehicles. This session will review the challenges and trends of FCEVs, and more specifically delve deeper into the following:

• Operating Principles
• Hydrogen storage  
• Fuel Cell types and main features. Advantages, weaknesses, and areas of application
• Overview across major markets trends (US, China, Europe, and Japan)

Toyota is the 2nd best-selling car brand in Europe with a high percentage of electrification. The Toyota Hybrid System (THS) is now in its 5th generation and is locally produced in Poland for Toyota’s vehicle assembly plants in multiple European locations. The presentation will introduce Toyota’s powertrain engineering activities in Europe and give an insight how collaborations with local suppliers result in competitive and affordable products for the diverse markets. 

• Collaborative engineering between OEM and Supplier 

• Optimization of technical specifications 

• Local validation and testing