EV Engineering

This final part of the multipart FAQ will explain the mechanical assembly and soldering process used to make joints during electric vehicle (EV) battery production. Although these two mechanisms are somewhat primitive in nature, they still find applications for making low-cost EVs where the makers do not have access to automation and advanced technologies. Mechanical…

This third part of the multipart FAQ will discuss magnetic pulse welding, micro-TIG, and clinching for electric vehicle (EV) battery productions. While the first two mechanisms use high temperatures to make joints, the clinching mechanism is based on applying force to create mechanical interlocking to create joints. All three mechanisms are less popular than the…

Resistance spot welding and wire bonding are popular choices for creating joints during EV battery production. However, every joining technology comes with a trade-off, giving packaging engineers room to select the appropriate one for their battery design. This is the second part of the multipart FAQ on the joining methods for EV battery production and…

Joints are important electrical and mechanical connections in producing electric vehicle (EV) batteries. They link individual battery cells to make a full battery pack. However, the process of making joints has evolved over the years due to various technologies. This first part of the multipart FAQ will discuss ultrasonic welding and laser welding, two commonly…

NXP Semiconductors has announced the MC33777, a battery junction box integrated circuit (IC) that combines sense, think, and act capabilities for battery management systems. The MC33777 integrates pack-level functions into a single device, which differs from conventional solutions that use multiple discrete components, external actuators, and processing support. The MC33777 IC monitors battery current and…

Samsung recently announced the development of a groundbreaking solid-state electric vehicle (EV) battery (Figure 1), promising a 600-mile range, 9-minute rapid charging, and a 20-year lifespan. In contrast, EVs with conventional lithium-ion (Li-ion) batteries typically offer a 250 to 350-mile range, 25 to 30-minute rapid charging, and an 8 to 15-year lifespan. Although many major…

First-generation solid-state batteries are poised to boost the driving range of electric vehicles (EVs) by 50% to 80%. Solid-state batteries could extend this range even further, with some automotive manufacturers ambitiously targeting 900 to 1,000 miles per charge. This article reviews how solid-state technology increases EV battery capacity and range, discussing lighter and more energy-dense…

Lithium-ion (Li-ion) battery traction packs power most electric vehicles (EVs) on the road today. These batteries enable electric motors to efficiently generate the high torque required for rapid acceleration and consistent speeds. Although Li-ion batteries offer high energy density and a relatively long lifespan, many automotive companies are actively researching and developing solid-state battery technology.…

Many automotive manufacturers classify new cars and trucks as software-defined vehicles (SDVs). As SDVs by design, electric vehicles (EVs) optimize vital systems and functions with sophisticated artificial intelligence (AI) and machine learning (ML) capabilities. This article discusses AI’s crucial role in EVs, from smart charging and advanced driver assistance systems (ADAS) to predictive maintenance and…

Battery technology is the foundational element of electric vehicles (EVs), influencing their efficiency, range, charging speed, lifespan, cost, and overall performance. Engineering firm Bosch Rexroth is well aware of how battery manufacturing affects every one of these factors. It believes innovations in battery technology and advanced manufacturing processes are essential for the widespread adoption and…