The Grid Carbon-fibre material can store electrical energy Coated carbon fibres are used as the current collector at the anode, with a glass-fibre separator isolating them from the uncoated fibres used for the cathode. The electrolyte runs between the fibres, and the current is collected by an aluminium foil at the anode and a copper foil at the cathode. Choice of coating is key to the battery’s energy density, including materials to generate the lithium ions. The carbon fibre can be optimised to provide a similar function to the graphite carbon used in existing battery cells. For passenger aircraft to be powered by electricity, they need to be much lighter than they are today. Weight reduction is also vital for road vehicles, extending driving range per charge. “Storing electrical energy in carbon fibre may perhaps not become as efficient as traditional batteries, but since our carbon fibre also has a structural load-bearing capability, very large gains can be made at a system level,” says CEO Markus Zetterström. A study from Chalmers shows carbon fibre-based structural batteries could increase the driving range for lightweight EVs by 70%. BATTERIES 8 SOFTWARE Powering two- to three-wheelers in Asia FRIWO has developed a motor control unit and software specifically for two- and three-wheel vehicles in Asia, writes Nick Flaherty. The MC1.5-55A-48V unit has a continuous power output of 1.5 kW for light EVs using permanent magnet synchronous motors (PMSM), making it ideal for electric scooters, motorcycles and other vehicles, particularly in India, Vietnam and Indonesia, and generally in Southeast Asia. The unit takes a supply voltage of 30-72 V, making it flexible for a wide range of battery pack designs, and it produces a motor current of 100 A RMS. This is capable of handling demanding tasks such as hill starts. Two analogue inputs allow the integration of sensors such as accelerator handles or brakes, and the software allows control and configuration of nine digital inputs. Communication is via the CAN protocol for integration with existing systems and networks. The unit is sealed to the IP65 rating for the harsh environments regarding temperature and humidity that e-scooters and light three-wheel vans encounter in Southeast Asia. The flexible, specially developed firmware of the MC1.5-55A-48V can be configured by the FRIWO Enable Tool. This measurement and calibration software sets the parameters of the motor and battery management system, enabling developers to update the firmware of the control unit. It also allows the parameter memory to be read out quickly to speed up integration and commissioning. The Enable Tool can adjust a wide range of parameters per control unit, allowing the subjective driving experience to be tailored to the customer’s requirements. The software also creates securely signed data sets for production and after-sales applications. This provides security and integrity by managing different user roles, such as developer, production and service, enabling efficient control of vehicle projects, even in larger organisations with a network of partners. A spinout from Chalmers University, Sweden, has developed a carbonfibre material that stores electrical energy and forms part of an EV’s structure, writes Nick Flaherty. Sinonus is commercialising a conformal battery using the material that doubles as electrodes. It has demonstrated the potential of its technology by replacing AAA batteries in low-power products in its lab. It is expanding to EVs and aircraft. It uses the conductivity of the carbon fibre developed by Oxeon, another Chalmers Venture company, which was used in the propeller blades for NASA’s Ingenuity helicopter on Mars. It was chosen by the engineering team for its ultralight weight and thinness. July/August 2024 | E-Mobility Engineering Sinonus’ composite battery cell FRIWO’s unit has a power output of 1.5 kW
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