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Rise In Demand For Electric Vehicles To Reduce Carbon Footprint To Create Opportunities In Lithium-Ion Battery Packs Market

Rise In Demand For Electric Vehicles To Reduce Carbon Footprint To Create Opportunities In Lithium-Ion Battery Packs Market

The emergence of lithium-ion batteries has been phenomenal. With the rising awareness about environmental conservation around the world, many individuals switched toward buying products or items that have a lower negative impact on the environment. As lithium-ion battery packs are used extensively in such products, the market will expand at a healthy CAGR of 11 percent across the forecast period of 2021-2031, to surpass a valuation of US$ 120.3 bn by 2031 according to a report by Transparency Market Research (TMR).

Lithium-ion battery packs are rechargeable batteries mainly used for electric vehicles and portable electronic items. These battery packs are eco-friendly alternatives to store energy and do not contain high levels of heavy metals that are harmful to the environment. All these aspects act as prominent growth generators for the lithium-ion battery packs market.

The demand for hybrid vehicles and electric vehicles has increased exponentially across various regions. The growing demand for these vehicles has led to an increase in the demand for lithium-ion battery packs, which will positively influence the growth of the global market for lithium-ion battery packs market.

Furthermore, government bodies of numerous countries are increasing their efforts to reduce carbon emissions across their regions. Various agreements such as the Paris Climate Agreement have been signed to speed up the process of decarbonisation. Densely populated countries like India are encouraging the production of electric vehicles through initiatives like Faster Adoption and Manufacturing of Hybrid and Electric Vehicles (FAME) and others. Thus, these factors are helping in increasing the growth opportunities across the lithium-ion battery packs market.

 

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Driving Hard On The Race Track: Wear-Resistant Iglidur Gears In The Gearbox

Driving Hard On The Race Track: Wear-Resistant iglidur Gears In The Gearbox

The iglidur I6 gears from the 3D printer for car racing of the “Youth Discovers Technology” (Jugend entdeckt Technik – JET) challenge

Electromobility is a crucial topic of the future. For Germany to be in the pole position, it is important to inspire young minds to take up scientific and engineering professions. Towards this purpose, the annual JET Challenge takes place at the IdeenExpo in Hanover. Students are given the task of building a fast, tough and energy-efficient racing car from a standard, remote-controlled car with a limited budget. Wear-resistant 3D-printed gears from igus made from the high-performance plastic iglidur I6 helped in this endeavour.

Build a fast, energy-saving racing car from an ordinary, remote-controlled car and overtake all other teams in a race – that’s the goal of the “Youth Discovers Technology” (Jugend entdeckt Technik – JET) Challenge, organised by the Society of German Engineers (Verein Deutscher Ingenieure – VDI) and the University of Hanover (Hochschule Hannover – HSH). As with the renowned models, the key factor is not speed alone, but also energy efficiency. In June 2019, visitors to the IdeenExpo can see the JET Challenge in action at the HSH trade fair stand. 25 teams compete for victory with their racing cars on a 1:10 scale on a 20-metre race track. The rules are strict. Available to each team is a budget of just 50 euros. Apart from battery, motor and speed controller, all components must be purchased, developed or built by yourself.

Save money with the igus 3D printing service

The teams are currently preparing for the next IdeenExpo. Students of the Eugen Reintjes vocational school are relying on a wear-resistant and tough gear transmission to enhance the performance of their race car. The biggest difficulty with this gearbox was the gear procurement. Due to the small budget, the students couldn’t afford big innovations. Finally, they found what they were looking for at the motion plastics specialist igus in Cologne: cost-effective, low-wear gears from the SLS printer. After a simple online configuration, the gears were printed and provided, made from the high-performance plastic iglidur I6.

High performance plastic makes race cars tough

Laboratory tests prove that the material I6 is significantly tougher than other plastics. In an experiment at our in-house test laboratory, the engineers tested gears made of polyoxymethylene (POM) and iglidur I6 at 12 revolutions per minute and loaded with 5Nm. A machined gear made of POM failed after 621,000 revolutions, while iglidur I6 was still in very good condition after one million revolutions. Thus, the team does not have to worry about potential failures. The gears in the racing car have already successfully completed an initial test run. The car is energy efficient and still reaches the top speed of 60km/h.

The young engineers support from igus promotes innovative projects

Innovative projects such as the race car gears for the JET Challenge are supported by igus as part of the young engineers support. The initiative supports young pupils, students and inventors in the development and execution of their technical projects.

 

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BMW And Ford Lead $130 Million Investment In Start-Up For Solid-State Batteries

BMW And Ford Lead $130 million Investment In Start-Up For Solid-State Batteries

Solid Power, an industry-leading producer of all solid-state batteries for electric vehicles has announced a $130 million Series B investment round led by the BMW Group, Ford Motor Company and Volta Energy Technologies. Ford and the BMW Group have also expanded existing joint development agreements with Solid Power to secure all solid-state batteries for future electric vehicles.

The investment positions Solid Power to produce full-scale automotive batteries, increase associated material output and expand in-house production capabilities for future vehicle integration. The BMW Group and Ford aim to utilise Solid Power’s low-cost, high-energy all solid-state battery technology in forthcoming electric vehicles.

“BMW and Ford now share leading positions in the race for all solid-state battery-powered electric vehicles,” said Doug Campbell, CEO and co-founder of Solid Power. “Solid Power now plans to begin producing automotive-scale batteries on the company’s pilot production line in early 2022 as a result of our partners’ continued commitment to Solid Power’s commercialisation efforts.”

Solid Power has demonstrated its ability to produce and scale next-generation all solid-state batteries that are designed to power longer range, lower cost and safer electric vehicles using existing lithium-ion battery manufacturing infrastructure.

Solid Power’s leadership in all solid-state battery development and manufacturing has been confirmed with the delivery of hundreds of production line-produced battery cells that were validated by Ford and the BMW Group late last year, formalising Solid Power’s commercialisation plans with its two long-standing automotive partners.

“Solid-state battery technology is important to the future of electric vehicles, and that’s why we’re investing directly,” said Ted Miller, Ford’s manager of Electrification Subsystems and Power Supply Research. “By simplifying the design of solid-state versus lithium-ion batteries, we’ll be able to increase vehicle range, improve interior space and cargo volume, deliver lower costs and better value for customers and more efficiently integrate this kind of solid-state battery cell technology into existing lithium-ion cell production processes.”

“Being a leader in advanced battery technology is of the utmost importance for BMW. The development of all solid-state batteries is one of the most promising and important steps towards more efficient, sustainable, and safer electric vehicles. We now have taken our next step on this path with Solid Power,” said Frank Weber, Member of the Board of Management BMW AG, Development.

Solid Power is currently producing 20 ampere hour (Ah) multi-layer all solid-state batteries on the company’s continuous roll-to-roll production line, which exclusively utilises industry standard lithium-ion production processes and equipment.

Both Ford and the BMW Group will receive full-scale 100 Ah cells for automotive qualification testing and vehicle integration beginning in 2022. Solid Power’s all solid-state platform technology allows for the production of unique cell designs expected to meet performance requirements for each automotive partner. Solid Power’s truly all-solid cell designs achieve higher energy densities, are safer and are expected to cost less than today’s best-performing lithium-ion battery cells.

 

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Evonik’s Research Hub In Singapore Launches New Line Of Photopolymers For 3D Printing

Evonik’s Research Hub In Singapore Launches New Line Of Photopolymers For 3D Printing

Evonik has developed two photopolymers for industrial 3D printing applications and introduces them under the brand names INFINAM TI 3100 L and INFINAM ST 6100 L. The two ready-to-use materials were conceptualised and invented in Evonik’s research hub in Singapore. They mark the start of a new product line of polymer resins suitable for use in common VAT polymerisation technologies such as SLA or DLP.

“With the new product line, we are entering the market-relevant photopolymer technology stream, strengthening our long-term market position as materials experts for all major polymer-based 3D printing technologies,” says Dr. Dominic Störkle, head of the Additive Manufacturing Innovation Growth Field at Evonik. “With the new ready-to-use formulations, we are also continuing our materials campaign and driving industrial-scale 3D printing as manufacturing technology along the entire value chain.”

Starting signal for a new photopolymer product line

The first high-performance material from Evonik’s photopolymer product family leads to high toughness and impact-resistant 3D parts. The combination of properties makes INFINAM TI 3100 L the new standard for additive manufacturing of industrial components using VAT polymerisation technologies such as SLA and DLP. The impact resistance measured on printed components is 30 J/m3 with a high elongation at break of 120 percent. The new material can therefore withstand strong impact or permanent mechanical effects such as pressing or impact. The range of possible applications extends from industrial to automotive parts and individual applications in the consumer goods sector, which, in addition to design-free forms, require strong mechanical loads in object use.

The second formulation is setting-up a new benchmark in high strength photo-resin category with a combined tensile strength of 89 MPa, flexural stress of 145 MPa and HDT of 120 deg C, which fills the material gap in ultra-high strength photopolymers. These special material properties make INFINAM ST 6100 L the material of choice for applications which need high temperature resistance combined with high mechanical strength.

 

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Electrification In The Automotive Industry

Electrification in the Automotive Industry

The automotive industry is on the brink of colossal changes. Marat Faingertz of ISCAR looks into the impact of this trend on the metalworking industry, and how new machining requirements can be addressed.

Public awareness of global warming, together with a pressing concern to create and maintain a clean environment, has led to a series of legislations worldwide that is forcing automakers to decrease CO2 emissions. Apart from improving fuel consumption, downsizing engines, and making lighter vehicles, automakers must turn to new technologies in order to cope with these emission limitations.

A rapid increase in battery electric vehicle (BEV) development, manufacture, and implementation, shows that electric vehicles are not only the future but are, in fact, the present. The automotive industry is on the brink of colossal changes and soon our perception of cars and transportation may alter completely.

ISCAR, a company with many years of experience in the production of metal cutting tools, offers unique, cutting-edge solutions for the new BEV Industry. As a leader in providing productive and cost-effective machining solutions, ISCAR strives to stay up to date with all the new trends and technologies and be a part of a brighter, greener future.

The following is a list of some of the common component machining processes in the BEV industry and some of the leading possible machining solutions and recommendations for each part.

Stator Housing Machining

One of the most notable trends of the electric vehicle powertrain is its simplicity. There are far fewer moving parts compared to the traditional internal combustion engine (ICE), therefore, manufacturing time and cost dramatically drop when producing BEVs. 

One of the main components of an electric motor is the motor (stator) housing made from aluminium. A special approach is needed to achieve this part’s critical key characteristics of lightweight, durability, ductility, surface finish and precision, including geometrical tolerances. The partially hollow form represents an additional challenge and maintaining low cutting forces is essential for roughness and cylindricity requirements.

ISCAR’s complete machining solution for this process has facilitated the transformation from the standard costly lathe-based process to an economical machining centre. Our aim is to reduce scrapped parts and reach an optimal CPK ratio (Process Capability Index—a producer’s capability to produce parts within the required tolerance).

Main Diameter Reaming

The most challenging operation in machining the aluminium stator housing is the main diameter boring and reaming. Because of the trend to use low power machines, the tool’s large diameter and long overhang require creative thinking to minimise weight and spindle load while maintaining rigidity. Exotic materials such as titanium and carbon fibre are used for the tool body, as well as the welded frame design.

The use of Finite Element Method (FEM) helps resolve the obstacles associated with this challenging application by enabling the consideration of many parameters, such as cutting forces, displacement field during machining, natural frequency, and maximum deformation.

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Toyota Electrification Plans To Boost Presence In Asia-Pacific EV Market

Toyota Electrification Plans To Boost Presence In Asia-Pacific EV Market

Toyota is set to unveil the concept version of the first model in its new battery electric vehicle (BEV) series, the Toyota bZ4X, in Shanghai and establish a full line-up of EVs to reduce CO2 emissions with the aim of having 70 electrified models by 2025.

Following this news, Bakar Sadik Agwan, Senior Automotive Consulting Analyst at GlobalData, a leading data and analytics company, offers her view:

“Toyota presently has only 4 BEVs in its portfolio and the new launches will enhance its position in the Japan and global BEV market. Several global OEMs, including Toyota, presently do not have a strong BEV portfolio due to their strategic priorities, low volumes and profitability concerns with battery vehicles. But the EV scenario has changed rapidly and there are significant opportunities in EV space due to push from the regional governments, reduction in costs and the availability of wide-range of products.

In addition to global market, Toyota’s BEV portfolio expansion will help it to tap significant opportunities in its home market, Japan, which presently does not have attractive BEV offerings and is witnessing high growth in demand for BEVs from select players such as Nissan and Tesla. Nissan’s Leaf is the only popular and successful BEV available for the mass market in Japan. While Tesla caters to the premium segment with sales of nearly 2,000 units annually.

In the recent past, Asia-Pacific has witnessed major developments in the EV market. Players such as Hyundai are trying to lead with innovative products and standout features while technology companies such as Huawei, Sony and Xiaomi are trying to penetrate the BEV market. The market is getting fiercely competitive day by day and automakers need to respond with suitable products to make their future sustainable.”

 

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Servo Forming—Enabling Highly Contoured Automobiles And Higher Productivity

Servo Forming—Enabling Highly Contoured Automobiles and Higher Productivity

To accommodate difficult-to-form materials, higher tonnage, higher energy and lower speeds, are the main requirements. Article by AIDA Engineering.

There is a global ambition to reduce carbon emissions. As more and more countries enact ever-stricter emission standards, the usage of new materials such as aluminium and high tensile strength steels has increased. Because of concerns about aggravating global warming, emission standards for automobiles have become even more stringent throughout the world. 

For example, the US Corporate Average Fuel Economy (CAFE) Standards raise mileage standards incrementally, and auto manufacturers around the world are trying to find ways to improve fuel efficiency. One key to better fuel efficiency is a lighter vehicle. 

The expectation is not only to achieve lighter vehicles and better passenger safety, but also to produce a sleeker design. Composites reinforced with carbon fibre have made some inroads with automakers because of the high strength-to-weight ratio and stiffness-to-weight ratio. Ford’s F-150 truck shed close to 15 percent of its vehicle weight, about 700 lb, by replacing conventional steel parts with high-strength, military-grade aluminium.

There is a growing need in automotive-related industries for new high-quality and high-efficiency forming technologies. New forming machinery is required for difficult-to-form materials, like advanced high-strength steels, and non-ferrous materials, like aluminium. With higher fuel economy driving the transition to lighter-weight vehicles throughout the world, automotive manufacturers are increasingly using high-strength steel and aluminium in order to achieve the material strength required to assure vehicle collision safety performance.

Difficult-to-form materials require a great deal of force for forming and, after forming, can have significant internal stresses that can lead to springback and cracks. They can also easily damage the forming dies. For instance, advanced high-strength steels (AHSS)—dual-phase grades with tensile strength up to 1,200 MPa, transformation-inducted plasticity, martensitic and twinning-induced plasticity steels—are more difficult to form than mild steels, and thus, product cracking issues can occur when formed using conventional mechanical presses. As for aluminium materials, they have limited elongation properties, which makes it difficult to form complex shapes. In addition, because aluminium is not magnetic, it cannot be conveyed using conventional magnetic transfer systems. 

At the same time, appealing body designs with complex curved surfaces are also being pursued in order to enhance consumer appeal, and as a result, the forming processes themselves have become more difficult. These kinds of problems are difficult to resolve using conventional technologies.

Press forming system provider AIDA is leveraging its independently developed servo technologies to provide solutions to these complex forming issues. AIDA servo presses are powered by servo motors that enable the precise control of the press slide motion, including the forming speed. The innovative servo technologies—such as the development of servo motors that can output high torque even at low speeds and servo-controlled die cushions with freely programmable pressure settings—enable not only the high-precision forming of new materials but also the forming of highly contoured vehicle bodies.

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VinBus Operates First Smart Electric Bus In Vietnam

VinBus Operates First Smart Electric Bus In Vietnam

VinBus Ecology Transport Services Limited Liability Company has opened and put into operation the first smart electric bus in Vietnam. The first electric bus lines will operate in Vinhomes Ocean Park (Gia Lam) and connect with the city’s public passenger transport system in the coming time.

VinBus is an electric bus model manufactured and assembled by VinFast at the Automobile Manufacture Complex in Hai Phong, combining many modern technologies with the smartest and safest features according to the strategy of current VinFasts smart electric bus series.

As smart electric buses, VinBus provides passengers with an outstanding comfort and safe experience. Buses are equipped with the automatic system that controls the drivers behaviour and warns unsafe dangers; automatic lowering mode of the bodywork suitable for the elderly, children, disabled persons, pregnant women; Electronic board announces the upcoming stop; Free WiFi, USB charging port, entertainment monitor and security camera system and itinerary control, turning back alarm, parking monitoring

VinBus owns a battery capacity of 281 kWh, capable of moving up to 220 – 260km. Buses are fully charged after only 2 hours at VinBuss 150kW fast charging station system with the worlds leading charging technology provided by StarCharge.

All buses of VinBus will be managed and operated intelligently through centralized monitoring, charging, safety inspection, maintenance, repair, and automatic cleaning at Depot stations scientifically arranged according to VinBus primary lines. The construction standard of the Depot stations is on a campus of more than 1 hectare, the roof equipped with solar panels, ensuring energy supply for Depot activities, contributing to reducing the pressure load of the power source for the national power system, environmental protection.

 

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Toyota Industries Corporation And Siemens Partner On Digital Transformation For Die Casting

Toyota Industries Corporation And Siemens Partner On Digital Transformation For Die Casting

To support their goal of manufacturing quality parts, Toyota Industries Corporation and Siemens have cooperated to develop artificial intelligence (AI) that can predict product abnormalities in aluminium die casting, a key process in automotive air conditioning compressor production.

The development is one of the world’s first to use defect prediction AI for die casting. It improves quality and productivity by utilising the AI application in Industrial Edge, the Siemens edge computing platform for industry. The initiative is an innovative example of digital transformation in manufacturing, and Toyota Industries Corporation aims to use it to further evolve their technology and incorporate it into their production plants in Japan and overseas. Siemens hopes that more businesses in the manufacturing industry will adopt their digitalisation and automation solutions such as Industrial Edge.

Aluminium die casting is a high-speed moulding process in which molten aluminium is shot into a die at high pressure. It is ideal for the accurate manufacture of metal cast parts that demand high dimensional precision, and therefore is often used for automotive parts that require high quality and reliability.  The die casting process is challenging to manage due to a range of constantly changing production conditions such as variations in the molten aluminium temperature or the injection rate. Success relies on the judgement of experienced workers, and sometimes the parts require secondary processing to handle abnormalities and maintain high quality standards.

During development, the two companies used a Siemens Simatic S7-1500 controller to gather big data totaling approximately 40,000 data points per die casting shot at the model line and then analysed the data using AI technology. They succeeded in preventing defects and improving quality by monitoring the production status in real time and automatically predicting equipment abnormalities that lead to quality issues. The production data is processed by the defect prediction AI on Industrial Edge, enabling instant analysis of the data on production conditions at the time of a shot and assessment of the part quality immediately after the casting. This series of AI technologies boosts productivity, improves quality, and transforms how operators work

“Digital transformation is a game changer. I am delighted to have the opportunity to partner with Toyota Industries Corporation in this revolutionary endeavor and to work together to forge the future,” says Rainer Brehm, CEO of Factory Automation, Siemens AG. “We will continue to develop and provide solutions for industries incorporating the latest technologies and to contribute to optimised and sustainable manufacturing.”

 

 

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Driving Hard On The Race Track: Wear-Resistant Iglidur Gears In The Gearbox

Driving Hard On The Race Track: Wear-Resistant iglidur Gears In The Gearbox

The iglidur I6 gears from the 3D printer for car racing of the “Youth Discovers Technology” (Jugend entdeckt Technik – JET) challenge

Electromobility is a crucial topic of the future. For Germany to be in the pole position, it is important to inspire young minds to take up scientific and engineering professions. Towards this purpose, the annual JET Challenge takes place at the IdeenExpo in Hanover. Students are given the task of building a fast, tough and energy-efficient racing car from a standard, remote-controlled car with a limited budget. Wear-resistant 3D-printed gears from igus made from the high-performance plastic iglidur I6 helped in this endeavour.

Build a fast, energy-saving racing car from an ordinary, remote-controlled car and overtake all other teams in a race – that’s the goal of the “Youth Discovers Technology” (Jugend entdeckt Technik – JET) Challenge, organised by the Society of German Engineers (Verein Deutscher Ingenieure – VDI) and the University of Hanover (Hochschule Hannover – HSH). As with the renowned models, the key factor is not speed alone, but also energy efficiency. In June 2019, visitors to the IdeenExpo can see the JET Challenge in action at the HSH trade fair stand. 25 teams compete for victory with their racing cars on a 1:10 scale on a 20-metre race track. The rules are strict. Available to each team is a budget of just 50 euros. Apart from battery, motor and speed controller, all components must be purchased, developed or built by yourself.

Save money with the igus 3D printing service

The teams are currently preparing for the next IdeenExpo. Students of the Eugen Reintjes vocational school are relying on a wear-resistant and tough gear transmission to enhance the performance of their race car. The biggest difficulty with this gearbox was the gear procurement. Due to the small budget, the students couldn’t afford big innovations. Finally, they found what they were looking for at the motion plastics specialist igus in Cologne: cost-effective, low-wear gears from the SLS printer. After a simple online configuration, the gears were printed and provided, made from the high-performance plastic iglidur I6.

High performance plastic makes race cars tough

Laboratory tests prove that the material I6 is significantly tougher than other plastics. In an experiment at our in-house test laboratory, the engineers tested gears made of polyoxymethylene (POM) and iglidur I6 at 12 revolutions per minute and loaded with 5Nm. A machined gear made of POM failed after 621,000 revolutions, while iglidur I6 was still in very good condition after one million revolutions. Thus, the team does not have to worry about potential failures. The gears in the racing car have already successfully completed an initial test run. The car is energy efficient and still reaches the top speed of 60km/h.

The young engineers support from igus promotes innovative projects

Innovative projects such as the race car gears for the JET Challenge are supported by igus as part of the young engineers support. The initiative supports young pupils, students and inventors in the development and execution of their technical projects. Further information on yes can be found at http://www.igus.sg/yes.

 

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