Optimum electric powertrain on the road Helix develops and manufactures powerful, compact, efficient electric powertrains for automotive applications. As a full-service supplier we make high performance accessible through Scalable Core Technology in our motor and inverter product ranges. We’re ready to meet your challenge. A story 25 years in the making. Become part of the next chapter. Visit us at The Battery Show, Novi, USA Stand 2501, UK Pavillion To find out more scan the QR code or visit ehelix.com www.emobility-engineering.com READERSHIP ABOUT US Launched in 2018, E-Mobility Engineering is the first publication to focus entirely on providing independent coverage of electric vehicle engineering. Now published bi-monthly, E-Mobility Engineering probes today’s cutting-edge projects to provide engineers with in-depth research insights, rigorous investigation backed by peer review and critical analysis. 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Trusted by engineers around the world actively working on developing solutions for electric vehicles. Written by engineers for engineers, our content is designed to engage, educate and inspire from an unbiased point of view. individually mailed copies per year per year (average 3 readers per copy) per year Average per month PRINT 6,000+ 18,000+ 728,000+ 1.74m+ 8.3% 380,000+ Core Circulation Readership Page views Unique Users Impressions Engagement WEBSITE SOCIAL • Chief Engineer • CTO • Technical Director • Head of Engineering • Head of E-Mobility • Head of R&D • VP of Engineering • Lead Engineer • Principal Engineer • Modelling & Simulation Engineer • Design Engineer • Electronic Design Engineer • R&D Engineer • Project Manager • Project Engineer • PHEV Engineer • BEV Engineer • HEV Engineer • E-Drive Engineer • E-Propulsion Engineer • Powertrain Engineer • Drivetrain Engineer • Electronic Engineer • Senior Engineer • Hybrid Engineer • Engineering Director • Hardware Engineer • Materials Manager • Technology Researcher • Systems Integration Engineer • Research Scientist • Embedded Software Engineer • Battery Engineer • Chemical Engineer • Electrical Engineer READER LOCATIONS: READERS INCLUDE: THE COMMUNICATIONS HUB OF THE ELECTRIFIED POWERTRAIN Protection agencies Let’s stick together Trends in fuse and circuit protection technologies Latest advances in adhesives for EVs Commercial enterprise Development details of the latest magniX e-powertrains for airliners Read all back issues and exclusive online-only content at www.emobility-engineering.com ISSUE 020 | JUL/AUG 2023 UK £15 USA $30 EUROPE €22 PRINT | DIGITAL | SOCIAL 32% USA 34% 14% 20% EUROPE UK REST OF WORLD 20 July/August 2023 | E-Mobility Engineering Rory Jackson looks at how these electric powertrains and their inverter have been designed for crewed aircraft integrators In every part of aerospace engineering, a race is on to break new ground and claim headlinegrabbing milestones in sustainable aviation. While it might seem to some that commercial airliners are moving at a sluggish pace compared with the automotive world in reducing their harmful emissions, it is not out of a lack of interest in decarbonisation. Regulatory bodies need to scrutinise the safety of new technologies intensely before allowing their use for transporting hundreds of millions of passengers a year. This need for safety means their approval of the use of biofuels and e-fuels for example in passenger jet powertrains has been glacially slow, compared with the rapid pace of innovation being achieved by new airgoing e-mobility groups. Of those, and not counting the spate of (crewed as well as uncrewed) eVTOL aircraft manufacturers that have emerged in the past 5 years, very few if any of them are aiming at the mass international transport of people that generates so much of the world’s CO2 output. Instead, a handful of SMEs are pioneering the case for eSTOL airliners that will one day become part of day-to-day life for anyone involved in commercial aviation, from private jets to large people carriers, and the industry’s attention has recently been drawn towards two successful test flights. Pilot programmes The magni650 (pictured) and magni350 are the latest generation of aircraft e-motors from magniX, capable of 700 kW and 350 kW respectively (Images courtesy of magniX) E-Mobility Engineering | July/August 2023 21 magniX magni350, 650 and magniDrive 100 | Dossier future, given the anticipated maturation of electric motor technologies. Meanwhile, the magni650 has an advantage in volumetric power density over the other three systems: the PW123B and PW123E both measure about 0.73 m3, compared to 0.2 m3 for the magni350 and 0.26 m3 for the magni650. However, if decarbonisation and energy efficiency in aviation are the ultimate goals, then the EPUs win out by some measure. In battery and hydrogen-electric aircraft, they will generate no carbon emissions and consume no jet fuel, with any specific fuel consumption being limited to hybrid configurations and the IC engine being used as a range extender. EPU development history As a company, magniX traces its origins back to 2005, when it was founded as Guina Energy on the Gold Coast of Australia, to pursue the founder Tony Guina’s passion for (and fundamental research into) electromagnetics across propulsion motors, generators and other applications. That led to some successes in developing superconducting technologies and accumulating a knowledge of magnetic field optimisation and shielding, for example. As David Sercombe, VP of the magni350/650 programme, recounts, “It was after 2015 that we decided we wanted to apply all that knowledge to the duty cycles and power demands in aviation, which are such that when you take off, you’re running at 100% power for a lot of time before you pull back to cruise. “That’s true whether the aircraft is powered by IC engines or electric propulsion, but our technological development had specifically targeted efficiency at high continuous power outputs, rather than say peak transients or thermal mass. Our motors have been designed to operate at One is the first flight of Eviation’s allelectric Alice airplane; in addition to its 19.2 m wingspan and nine-passenger capacity, it is also notable for being a clean-sheet design and batterypowered. The other is the first flight of Universal Hydrogen’s fuel cell-powered DHC8-Q300 aircraft, which with a 50- 56 seating capacity typically and a 27.4 m wingspan, was at the time of writing the largest electrified aircraft to have flown. These two cases represent fundamentally different approaches in terms of energy technologies, but they share a common approach in power output. Both have chosen their electric motor and inverters from the same supplier, US-based magniX, one of the few companies manufacturing electric powertrains specifically for crewed aircraft integrators. Its current offerings are the magni350 and magni650 EPUs (electric propulsion units). Each consists primarily of a permanent magnet synchronous AC motor and a set of motor inverters, as well as a constant-speed propeller mounted on the front of the motor and directly driven by the motor shaft, as well as an accessory gearbox for powering ancillary aircraft systems from the shaft. The EPUs both operate on an 800 V AC supply from their inverters. The magni350 has a mass of 128 kg with all inverters and HV cables, and can output power continuously up to 350 kW, while the magni650 weighs 206 kg with cables and inverters and produces up to 700 kW. For comparison, and for anyone seeking a benchmark against conventional aerospace powertrains, the standard-issue engine for the DHC8-Q300 is a Pratt & Whitney turboprop, either the PW123B or PW123E. The former has a dry weight of 450 kg and a maximum power of 1865 kW, while the latter weighs the same and produces up to 1775 kW. That gives the PW turboprops a very slight advantage in power-to-weight ratio, one unlikely to be retained in the The magniX EPUs have been used to power successively the largest electrified aircraft flown to date. The Eviation Alice flew in September 2022... ...while Universal Hydrogen’s De Havilland Canada DHC8-Q300 flew in March 2023 www.emobility-engineering.com CONTENT FOCUS Revisited just once every 2-3 years the ‘Focus’ acts as an excellent source of reference on specific products and types of engineering services – topics covered include: • Adhesives & Bonding • Anode Materials • Axial Flux Motors • Battery Case Materials • Battery Chemistry • Battery Coatings • Battery Inspection • Battery Manufacturing • Battery Materials • Battery Safety • Battery Surface Analysis • Battery Testing • Battery Welding • BMS • Busbars & Interconnects • Cabling & Connectors • Charging • Composites • eAxles • Electrode Materials • Charging • Fuel Cells • Fuses & Circuit Protection • HVAC & Climate Control • Immersion Cooling • Insulation • Inverters • Magnetics • Measuring Methods & Equipment • Motor Controllers • Motor Manufacturing • On-board Chargers • Polymer Materials • Power Electronics • Power Semiconductors • Powertrain Testing • Radial Flux Motors • Sealing • Thermal Management • Thermal Runaway prevention • V2H & V2G Bidirectional Charging THE GRID The E-Mobility Engineering news section is focused on technological development. Business and politics are only covered in so far as they impact directly on engineering solutions. From the outset, E-Mobility Engineering has established itself as a publication that deals in hard science. DOSSIERS The dossiers offer an incredibly detailed look at high-profile e-mobility projects, revealing many secrets of the technology that are simply not reported anywhere else. Our overall vehicle dossiers cover concepts from automotive, off-highway, aerospace and commercial applications. Each powerplant dossier explores in depth one of the diverse innovative power units at the forefront of today’s electric revolution. DEEP INSIGHTS E-Mobility Engineering’s insights drill down into specific technological topics, providing mission-critical information for engineers working in the field. This may be a deep dive into high-power semiconductor materials, through to an investigation into the challenges of hydrogen infrastructure. The running theme is unmatched insight and technical detail. IN CONVERSATIONS In each issue of E-Mobility Engineering we feature an in-depth interview with a notable engineer. The interviews chart the engineering history that led them to their current role, the projects they are working on and an insight into the development of those projects. WEB EXCLUSIVES Utilise the expertise of our editorial team by allowing them to interview your engineers, in order to generate a unique and independent article, that will appear under “The Grid” section. Published weekly, web exclusives engage engineers with thought provoking content covering the latest trends in the industry. NEW PRODUCT RELEASE Written by you, reviewed by us, released at a specific time, on a specific date. Published under our ‘resources’ section, new product releases provide the perfect opportunity to launch your latest advances, to be shared among the community who are best placed to take advantage of them. Digging deep Rory Jackson provides an in-depth report on how these heavy-duty excavators were converted to electric operation The construction industry is a major focus for many parties intent on fighting pollution and climate change, and with good reason: studies over the past few years estimate that construction contributes just shy of 40% of the world’s output of greenhouse gases. That figure, combined with the growing impetus to protect construction workers against the detrimental health effects of IC engine emissions, is shaping the industry’s demands and future regulations to favour low-carbon vehicles. While some responses to these changes take the form of LNG- and CNG-powered vehicles, which do lower emission outputs relative to diesel powertrains, electrifying construction equipment means eliminating all greenhouse gases at the point of use, so it’s the ultimate way to stay ahead of tightening carbon restrictions. While producing electric construction vehicles is challenging, given the heavy-duty applications for them, the market could be worth hundreds of billions once regulations begin coming into effect, making their ownership an urgent necessity for new building projects. It also means an enormous reduction in part counts and hence ownership costs for vehicle owners by swapping out IC engines for electrified powertrains. Small wonder then that electric conversions of excavator systems are now commercially available, thanks in part to Netherlandsbased Electric Construction Equipment (ECE). ECE is a subsidiary of Staad Group, which imports and distributes dieselpowered Doosan earth-moving vehicles. As ECE’s full name implies, it is responsible for providing electrified versions of the Doosan machinery, which are converted from IC engine power to battery-electric power at ECE’s facilities before being sold on to its clients. Some of these are large European construction companies, although ECE finds higher demand coming from the smaller subcontractors that work on behalf of the bigger firms. Through rigorous r&d, both inhouse and with key partners such as Webasto, ECE can now provide electric versions of different Doosan construction excavators. The two largest and most powerful of these are the DX165W Electric – which weighs roughly 17 t, has a bucket capacity of 0.64 m³, and can dig down to depths of 5.02 m – and the DX300LC Electric, a 34 t excavator with a 1.27 m³ bucket and a digging depth of 7.3 m. ECE has re-engineered Doosan’s excavators to conform with all future limitations on point-of-use emissions as The DX300LC Electric is an electrified Doosan construction vehicle weighing 34 t with a 1.27 m³ bucket (Images courtesy of ECE unless otherwise stated) 20 January/February 2023 | E-Mobility Engineering EME017_Dossier ECE.indd 20 23/11/2022 11:03 powerful excavators,” says Thijs Van Hal, COO of ECE. “At the time, we didn’t think there was much of a market for larger excavators, but in 2019 customers started querying directly if we could electrify some of Doosan’s bigger models, principally because the emissions rules for construction projects looked like they were starting to change. “For instance, by 2025, emissionsproducing cars and trucks won’t be allowed in many European city centres, and by 2030 there will be widespread bans on diesel-powered excavators in city centres.” Given Staad Group’s experience and inventory of the larger dieselpowered Doosan machines that customers wanted electrified, ECE had easy access to copious data on key powertrain constraints, such as the kinds of duties the vehicles performed and the rates of fuel consumption they exhibited during such duties. By analysing such metrics over the 200-or-so Doosan DX165Ws and DX300LCs that Staad has in operation, ECE was able to set targets that the two vehicles’ electric powertrains would need to achieve in areas such as voltage, current, onboard stored energy, and e-motor shaft speed and power. “Important goals included both machines needing to run for 8 hours between charges, they needed to have swappable batteries, and in general they needed to be safe,” Van Hal says. “There were some physical constraints and targets too. For instance, we were quite sure the battery packs would need to sit where the diesel engines had previously been installed, with some additional modifications to ensure sufficient counterweighting against the movements of the digger arms, and to keep the centre of gravity the same as in the IC engine-powered versions. “While running simulations in AutoCAD to determine the kinds of components we’d need to hit these targets, we started looking for suppliers of batteries and electric motors. We agreed the sale of the first units in late 2019, which were to be supplied in 2020.” The first half of 2020 was spent largely on selecting battery and electric drive systems, as well as integrating them into the two excavators. The summer and autumn through to the December were spent running tests to analyse well as provide a fit with the operating and maintenance procedures on construction sites, in particular how batteries are used, managed and handled. The company’s engineering philosophy therefore begins with numerous application-critical end points in mind, making it a useful study in practical EV digger design and execution. Electrifying Doosan’s excavators ECE’s first work on an electrified excavator began in 2018, which soon after resulted in the all-electric Doosan DX19. This was a small excavator that allowed the Dutch company to begin gathering and gauging interest in emissions-free systems for demolition jobs in indoor spaces, where ventilation is insufficient for conventional diesel- or LNG-powered systems. “It also meant we could start looking for partners and suppliers capable of shipping enough components for short production runs of the mini-excavator, in preparation for supplying larger quantities of more The DX165W is a smaller construction EV than the DX300LC, weighing in at 17 t and carrying 280 kWh of battery energy compared with the DX300LC’s 420 kWh January/February 2023 | E-Mobility Engineering 21 Dossier | ECE electric Doosan DX165W and DX300LC EME017_Dossier ECE.indd 21 23/11/2022 11:03 www.emobility-engineering.com NEWSLETTER AD RATES & SPECS E-Mobility Engineering advertisers benefit from supporting unbiased technical content through our tried and tested omnichannel approach. 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To achieve an optimal EV battery performance, CHT offers a complete package of solutions, including thermal interface materials, adhesives, gap fillers and lightweight potting compounds. In addition, we offer customized products to meet your individual design and functional requirements. Benefit from our expertise and experience in silicones. Learn more: www.cht-silicones.com EV BATTERY SPECIAL SILICONES AND FOAMS: PERFECT SUPPORT OF EV BATTERY MANUFACTURING LEARN MORE CHT-1903_AZ_EV_BATTERY_EN_92,5x277_230525.indd 1 25.05.23 14:39 Visit emobility-engineering.com and sign up to our exclusive monthly e-newsletter to keep up to date with the latest technological innovations,as they happen! Optimum electric powertrain on the road Helix develops and manufactures powerful, compact, efficient electric powertrains for automotive applications. As a full-service supplier we make high performance accessible through Scalable Core Technology in our motor and inverter product ranges. We’re ready to meet your challenge. A story 25 years in the making. Become part of the next chapter. Visit us at The Battery Show, Novi, USA Stand 2501, UK Pavillion To find out more scan the QR code or visit ehelix.com webasto-electrified.com In-House Prototyping & Testing Thermal Management for Optimal Performance Highest Quality & Safety Standards Integrated Plug-n-Play Battery Solution Cost effective, modular and scalable battery solutions for e-mobility applications. 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Space-saving battery cooling systems from technotrans are used in Europe, Asia, North and South America. They also cool converter substations in rail projects around the world. – www.technotrans.com www.emobility-engineering.com ISSUE 011 | AUTUMN 2021 UK £15 USA $30 EUROPE €22 E-MOBILITY ENGINEERING THE COMMUNICATIONS HUB OF THE ELECTRIFIED POWERTRAIN Salvage value Let’s stay together Overcoming the challenges of recycling EV batteries The importance of sealing technology – now and in the future Raising the standardWe get inside Candela’s C-7 hydrofoil speedboat EME_Issue 11 - Cover.indd 1 19/08/2021 15:09 ISSUE 014 | SUMMER 2022 UK £15 USA $30 EUROPE €22 E-MOBILITY ENGINEERING THE COMMUNICATIONS HUB OF THE ELECTRIFIED POWERTRAIN Best behaviour Time to pack them in? How to ensure fast and accurate battery monitoring Potential benefits of cell-to-pack batteries No restriction Green-G’s refuse collection EV for narrow streets EME014_Cover.indd 1 12/05/2022 12:31 ISSUE 009 | SPRING 2021 UK £15 USA $30 EUROPE€22 E-MOBILITY ENGINEERING THE COMMUNICATIONS HUB OF THE ELECTRIFIED POWERTRAIN All about EvaEnergica’s Eva Ribelle urban e-bike givesup its engineering secrets Nottoo hot, not too cold Power brokers How to keep EV batteriesattheir optimumtemperature The latestadvances in powerelectronics systems EME009_Cover.indd 1 12/02/2021 12:30 ISSUE 017 | JAN/FEB2023 UK £15 USA $30 EUROPE €22 E-MOBILITY ENGINEERING THE COMMUNICATIONS HUB OF THE ELECTRIFIED POWERTRAIN Gentle probing Not too hot, not too cold Non-destructive ways of testing EV batteries Thermal management solutions for EV battery charging and safety Sites of the future ECE’s work on electrifying Doosan excavators EME017_Cover.indd 2 23/11/2022 11:04 ISSUE 013 | SPRING 2022 UK £15 USA $30 EUROPE €22 E-MOBILITY ENGINEERING THE COMMUNICATIONS HUB OF THE ELECTRIFIED POWERTRAIN State of play Nearly there The challenges of developing solid-state batteries Why solar-powered EVs could soon be a common sight Off the grid How the Lightyear One solar EV could make plug-in charging a thing of the past EME013_Cover.indd 1 17/02/2022 16:48 ISSUE 012 | WINTER2021 UK £15 USA $30 EUROPE €22 E-MOBILITY ENGINEERING THE COMMUNICATIONS HUB OF THE ELECTRIFIED POWERTRAIN Moving on up Return of an icon Focus on the impacts of switching to 48 V systems How Everrati carried out its ‘resto-mod’ of a classic Porsche 911 Power couples Sigma Powertrain’s EMAX two-inone motor solution for heavy EVs EME_Issue 12 - Cover.indd 1 26/11/2021 15:55 ISSUE 010 | SUMMER 2021 UK £15 USA $30 EUROPE€22 E-MOBILITY ENGINEERING THE COMMUNICATIONS HUB OF THE ELECTRIFIED POWERTRAIN Quiet please We make a noise about how Irizar Group developed its urban ie truck Sound advice Consumer protection Focus on NVH and the tools EV engineers use to tackle it The latest developments in battery safety systems EME010_Cover.indd 1 17/05/2021 11:29 ISSUE 011 | AUTUMN 2021 UK £15 USA $30 EUROPE €22 E-MOBILITY ENGINEERING THE COMMUNICATIONS HUB OF THE ELECTRIFIED POWERTRAIN Salvage value Let’s stay together Overcoming the challenges of recycling EV batteries The importance of sealing technology – now and in the future Raising the standardWe get inside Candela’s C-7 hydrofoil speedboat EME_Issue 11 - Cover.indd 1 19/08/2021 15:09 THE COMMUNICATIONS HUB OF THE ELECTRIFIED POWERTRAIN Cases in point Testing times Focus on the growing range of battery case materials The new demands placed on making sure EV powertrains pass muster Platform player WAE’s development of its EVR skateboard for electric supercars Read all back issues and exclusive online-only content at www.emobility-engineering.com ISSUE 019 | MAY/JUNE 2023 UK £15 USA $30 EUROPE€22 ISSUE 018 | MAR/APR 2023 UK £15 USA $30 EUROPE €22 THE COMMUNICATIONS HUB OF THE ELECTRIFIED POWERTRAIN Multiple choice All due recognition Latest trend in battery management The uses and benefits of biometric technologies From zero to zero How Cake aims to make its Kalk e-bike emissions-free at every stage of its production THE COMMUNICATIONS HUB OF THE ELECTRIFIED POWERTRAIN Protection agencies Let’s stick together Trends in fuse and circuit protection technologies Latest advances in adhesives for EVs Commercial enterprise Development details of the latest magniX e-powertrains for airliners Read all back issues and exclusive online-only content at www.emobility-engineering.com ISSUE 020 | JUL/AUG 2023 UK £15 USA $30 EUROPE €22 2024 MEDIA KIT PRINT | DIGITAL | SOCIAL Scan to access our online content Brand new media kit for 2024 NOW LIVE! 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