Author: tsport100

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LG Chem plans to build electric car battery factory in Poland – source

South Korea's LG Chem plans to build an electric vehicle battery factory in Poland to meet rising demand from European automakers, a person familiar with the matter said on Thursday.

"The plant will be completed in about one-and-a-half years," said the source, who did not want to be named as he was not authorized to talk to the media. He did not provide any details on the size of the investment.

The facilities, to be located in the southwestern Polish city of Wroclaw, will ultimately have a production capacity of 229,000 EV batteries a year, making it LG Chem's second-biggest EV battery factory after China, the source said.

The company also builds EV batteries in South Korea and the United States.

LG Chem - the battery supplier for General Motors' upcoming electric car Bolt - counts a total of 25 automakers globally, including Renault, Volkswagen, Audi and Volvo in Europe, as its customers.

A spokesman for LG Chem said it was considering adding car battery production facilities, but nothing had been decided.

Automakers around the world are expected to roll out a slew of electric vehicles to meet tougher emissions and fuel economy regulations, although there are concerns that current low oil prices will dent demand for fuel-efficient cars.

LG Chem's rival Samsung SDI, which has BMW as one of its customers, is also considering building an EV battery factory in Europe, a Samsung SDI spokesman said.

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Electromagnetic Anti-Lock Braking for Electric Vehicles

In part 2 of this series (Part 1) we'll take a closer look at electromagnetic braking as a replacement for mechanical friction brakes in hybrid and electric passenger cars.

Electromagnetic braking is very well established in industrial applications. From 400 tonne mine haul trucks to 300 km/h Bullet trains, electromagnetic 'friction' is used to slow these high performance vehicles with industrial strength reliability, so why shouldn't it also be used on comparatively light weight private passenger vehicles ?

Lets take a look at a few of the more familiar applications of electromagnetic braking. Japan's Shinkansen high speed rail network has the best safety record on the planet: beating conventional trains, automobiles and flying. Over the Shinkansen's 50-plus year history, carrying over 10 billion passengers, there have been zero fatality / injury since 1964. Clearly many factors contribute to this but obviously the train braking system plays an important role, especially given the maximum operating speed is 320 km/h (200 mph).

Bullet trains uses electricity to brake up to 640 tonnes down from 300 km/h at a controlled and predictable deceleration rate. Since 1984 all Shinkansen trains have used axial flux eddy current disc brakes (pictured above). These work along the same lines as an eddy current dyno where a steel brake rotor has electromagnets facing it, that when energised, induce eddy currents in the rotor which generates electromagnetic friction that converts the trains kinetic energy into heat.

With the only moving part being the rotor and no wear and tear from mechanical friction, eddy current brakes have proved incredibly reliable and no doubt contribute to the 100% safety record achieved by the Shinkansen rail system. Since 2007 next generation Bullet trains have moved to regenerative braking that uses the main traction motors which helps increase overall system efficiency.

Another very large vehicle that uses electromagnetic brakes is the 400 t class Liebherr T282B Mine haul truck. with a maximum operating weight of almost 600 tonnes, the T282B has no mechanical connection between the monster 90 liter V20 twin turbo diesel engine and the rear wheels.

Instead it takes advantage of high efficiency and maintenance free diesel-electric locomotive technology. Siemens provide two AC induction motors for the rear axle, engine mounted generator and the solid state computer controlled power inverters that are proven over millions of operating hours in trains. The main service brake electric retarders can slow the truck to a stand-still and provide precise speed control on descent using built in cruise control which works in both drive and retard modes.

The electric retarders can apply over 6,000 hp (4,489 Kw) worth of braking effort (the Diesel ICE maximum output is 'only' 3650 hp (2700 Kw). Like the Bullet train there is no battery storage system on-board so the regenerated energy is not stored for later use but is converted to heat via a stainless steel resistor grid in a systems called dynamic braking.

If ultra-reliable electromagnetic braking of 600 tonne vehicles hasn't convinced you then surely this last example will. Strictly speaking this is called magnetic braking as the source is permanent magnets, yet it is just as impressive.

Drop Tower amusement park rides feature up to 400 feet (120 m) towers with a carriage capable of taking up to 40 passenger aloft. Once 30 stories off the ground, the 25 tonne carriage is dropped and free-falls back down the tower reaching speeds of 105 km/h. Built by Swiss firm Intamin, the eddy current magnetic brakes pull the falling riders up at 2.5G from 100 to 0 km/h within 100 feet.

To put that into perspective, a Tesla Model S brakes from 100 to 0 km/h in 113 feet, weighs only 2.5 tonne and moves parallel to the ground, not hurtling head-first towards it.

The common threat between all the above braking applications is that mechanical friction brakes would simply not be capable of reliably doing the job. While these electric braking systems convert kinetic energy into heat, as do hydraulic friction brakes, using electromagnetic friction offers a non-contact method of braking that virtually eliminates maintenance and therefore reliability issues.

In the previous post we've seen evidence that hydro-mechanical friction brakes on hybrids and EVs have become redundant legacy systems primarily still required on vehicles because they provide mandatory safety systems. In order to allow electromagnetic braking to functionally replace systems like ABS & ESC not only do we need each wheel to have an electric motor to drive / brake each wheel independently, but also additional electromagnetic braking strategies other then just regeneration feeding kinetic energy into a battery pack.

Currently in hybrid and electric vehicles only a fraction of the electric motors full power is used for braking. For example, a Chevy Volt has 115 kw of electric motor power available for acceleration but only 60 kw for braking. Even a Tesla Model S with over 500 kw for acceleration is limited to 60 Kw maximum brake regeneration. The primary reason for this is battery cell charge limits. Most lithium ion batteries have asymmetric charge & discharge curves.

In order to allow full electric motor power to be applied in brake mode, alternative energy discharge methods are required. As we have seen in the examples provided above, there are several options from dynamic to eddy current braking and/or the addition of supercapacitors in parallel with the battery pack. With an electric motor for each wheel and full motor power available for braking, modulating the motors independently to perform anti-lock, stability control, emergency brake assist, automatic emergency braking and torque vectoring becomes a software project.

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VW Push for All-Electric Rallycross Supercars

Volkswagen is considering the development of an all-electric rallycross supercar.

The German firm's head of technology Frank Welsch says the short, sharp format of rallycross events offers the perfect showcase for advances in electric car technology.

“I can certainly imagine a championship done with all-electric cars,” Welsch told Autocar. “The races are around six minutes long, which allows for short, intense bursts of competition and then charging.”

VW already competes in Red Bull Global Rallycross with factory Beetle GRCs and in FIA World Rallycross with Polo RXs. Both cars squeeze around 560 HP out of their tiny engines and reach 100km/h in just 2 seconds.

“Today these cars are super-powerful, have torque from hell and use all-wheel drive,” said Welsch. “Electric drivetrains could deliver that.”

Welsch went on to say that “If the championship moved that way it would be perfect for us.”

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Are Friction Brakes Redundant on Electric Vehicles & Hybrids?

The Toyota Prius, the world's first mass-produced hybrid vehicle, went on sale in Japan in 1997. 18 years later with sales surpassing 8 million vehicles, we're starting to get a clear picture of how durable vehicles powered by electric powertrains are.

The humble Prius has proved so durable, with regular news of taxi operators surpassing 1 million km (the record stands at 1.5M km), there is even a thread on the priuschat website designated for Prius owners who have passed 299,999 miles (480,000 km).

Not only are most Prius achieving these distances on the original battery pack (dispelling that urban myth) but in many cases they are also still on the original factory fitted set of brake pads!! With a Prius able to use brake regeneration down to 10 km/h, industry standard hydro-mechanical friction brakes move from being a system made up of consumable parts to being a durable system that last the life of the vehicle.

Typical brake pad life expectancy on an ICE car is between 50-100,000 km with brake rotors needing replacement every 100-200,000 km so the increase in Prius pad life is in the 10x region.

If the relatively low powered 50 kw electric motor / generator in the Prius has made friction brakes 95% redundant, then vehicles like the BMW i3 with a much more powerful electric motor (125 kw) and aggressive speed variable brake regeneration capable of bringing the car to a complete stop, make friction brakes entirely a legacy system whose only function is to provide very low duty cycle safety functions such as Anti-Lock Brakes (ABS) and Electronic Stability Control (ESC).

Taxi operators running fleets of Nissan Leaf are also reporting high mileage on original brake pads and no doubt given enough time will also pass 500,000 km without a pad &/or rotor change. Leaf owners have the added benefit of not having an ICE to service (Prius ICE's reportedly consume excessive oil above 500,000 km) and with typical electric motor life measured in the 20-40,000 hour range, electric only powertrains could last in excess of 2 million kilometres of trouble free motoring, compared to a typical ICE car life expectancy of 320,000 km (200,000 miles).

The more brake regeneration becomes a standard in the automotive world, the more inevitable the elimination of the dead weight and costs associated with legacy friction brake systems seems. In order to allow electromagnetic braking to functionally replace all mandatory safety systems like ESC, each wheel requires an electric motor to drive / brake each wheel independently.

Technologies that we take for granted these days — like stability control and anti-lock brakes — paved the way for computer-controlled cars, and these long-established safety technologies are mandated by NHTSA etc. Automakers today agreed to make automatic emergency braking standard in US by 2022. Automatic braking, like lane keeping and dynamic cruise control, is considered a precursor to fully autonomous vehicles.

The convergence of vehicle electrification and self-driving cars will accelerate the need to consolidate all vehicle dynamic controls for propulsion and braking within a single system, i.e. Software Eats the Automotive Powertrain.

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2017 BMW i3 to get 200 km (EPA) range, starts production in July

BMW will boost the range of its i3 electric car by about half for the 2017 model year.

This summer, the lithium ion battery pack of the compact EV will be improved, "which puts it into a much more usable range," Ian Robertson, BMW AG board member for sales and marketing, told Automotive News at the Detroit auto show.

BMW doesn't have the exact figure yet, but a 50 percent increase means about 200 km on a single charge, up from the current 130 km (EPA).

The 2017 i3 will begin production in July of 2016 and will use Samsung 94 Ah battery cells. The 2017 i3 needs the increase in range to compete with the 2016 30 kWh Nissan Leaf with 250 km range and the upcoming Chevy Bolt, which will have a range of 300+ km.

The i3 went on sale in the U.S. in the spring of 2014 and has a base price of $43,350 including shipping. A model with a range extender is also available -- with about double the range -- and starts at $47,200 including shipping. Those prices are before tax credits.

BMW sold 24,057 i3s worldwide last year, an increase of 50 percent from 2014. In the United States, BMW sold 11,024 i3s, up from 6,092 in 2014. Nearly 60 percent of those were with the range extender.

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GM Buying 3 yo Self-Driving Tech Startup for $1 Billion

General Motors announced Friday it is buying Cruise Automation, a San Francisco self-driving vehicle startup, the latest move by the auto company as it competes with Silicon Valley to develop self-driving cars that could be used in ride-sharing fleets.

GM and Cruise did not disclose the value of the deal. Technology website Re/Code cited sources as saying GM paid $1 billion. A GM spokesman declined to comment on that figure. If correct GM has just set a new precedent for valuations of automotive tech start-ups.

GM intends to use Cruise’s technology and people to accelerate its effort to develop vehicles that can operate without a human driver, potentially as part of ride-sharing fleets “as soon as possible,” GM President Dan Ammann said in an interview.

“We will be committing considerable resources to recruit and grow the capability of the team,” Ammann said.

Cruise has been working to develop hardware and software that could be installed in a vehicle to enable the car to pilot itself on a highway, without the driver steering or braking.

GM initially planned an investment in the company but moved within five weeks to buy Cruise outright, said venture partner Nabeel Hyatt of Spark Capital, an investor in Cruise.

"They moved faster than most Silicon Valley companies would move," he said.

Cruise, which has 40 employees, was launched in 2013 and has raised $20 million in venture capital, founder Kyle Vogt said in an interview.

Vogt impressed Silicon Valley venture capital fund Signia Venture Partners by demonstrating an Audi A4 that could be controlled by a game console, said Signia principal Sunny Dhillon.

More recently, Cruise was working on a system that could make a car "fully driverless," Vogt said.

A flurry of investments by traditional auto companies reflects a fear among industry executives that the century-old business of building and selling cars that people drive themselves is at risk, even though global vehicle demand is strong.

In January, GM said it would invest $500 million in ride-hailing company Lyft Inc and followed that by forming a new car-sharing operation called Maven. The company has also established a separate unit for self-driving vehicle development.

Other automakers are moving into ride sharing and self-driving vehicles, as are some traditional auto suppliers.

Germany’s Continental and Delphi Automotive among others are seeking technology companies to buy for intellectual property and programming talent.

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Panasonic & Bosch bid for Porsche Mission-E battery

Porsche AG has been weighing bids from Panasonic Corp. and Robert Bosch GmbH for a long-range battery as it prepares to challenge Tesla Motors Inc. with an all-electric sports car, according to people familiar with the matter.

Costs for the package offered by crosstown neighbor Bosch would be higher than the competing technology from Japanese peer Panasonic, which supplies Tesla’s batteries, said the people, who asked not to be identified because the talks are confidential. The advantage to Bosch’s offer would be less-complex logistics.

“We’re in the final stage of making a decision,” Porsche Chief Executive Officer Oliver Blume said in an interview last week at the Geneva International Motor Show. He declined to comment on the suppliers being considered.

The unit of Volkswagen AG, Europe’s largest automaker, earmarked 1 billion euros ($1.1 billion) to build its first battery-powered sports car in December. It’s part of the parent company’s broader push for more low-emission electric and hybrid cars. Volkswagen has sped up its electric efforts since admitting six months ago it had cheated on emissions tests for diesel cars.

Audi CEO Rupert Stadler said a week ago the company, a fellow Volkswagen unit, will purchase batteries for its electric vehicles from Korean suppliers LG Chem Ltd. and Samsung Electronics Co., who have plans in place to start producing battery cells in Europe.

Electric Investment

With the Volkswagen scandal throwing the long-term future of diesel into question, other carmakers are also turning anew to electric cars. Daimler AG’s Mercedes-Benz said last week it will invest 500 million euros to build a second battery factory in Germany because it expects demand to pick up.

Porsche’s electric sports car will be based on the low-slung Mission E concept shown at the Frankfurt auto show six months ago. Set to be produced near the automaker’s German headquarters in Stuttgart, the new model will create some 1,000 jobs.

A spokesman for Porsche referred to the brand’s annual earnings conference, scheduled Friday morning, and declined to comment beforehand. Bosch declined to comment. Yayoi Watanabe, a spokeswoman for Panasonic, declined to comment.

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Drive Unit and Battery at Heart of Chevrolet Bolt EV [VIDEO]

The 2017 Chevrolet Bolt EV does more than set a new benchmark for affordable, long-range EV driving. It also raises the bar when it comes to driving performance.

Engineers developed the Bolt EV’s propulsion system to offer more than an estimated 200 miles (based on GM estimates) and a peppy driving experience that’s more akin to a compact sports sedan than a small utilitarian crossover.

“Being the leader in range and affordability means nothing if the car isn’t going to excite you each time you get behind the wheel,” said Josh Tavel, Chevrolet Bolt EV chief engineer. “That’s why the team was tasked with delivering a propulsion system that would also make the Bolt EV an electric vehicle that owners would love to drive.”

Single Motor Drive Unit
Like most EVs on the road, the Bolt EV’s drive system uses a single high capacity electric motor to propel the car. But it’s the smooth, powerful and quiet motor design, gear configuration and shift-by-wire system that separates it from the pack.

The engineering team designed the Bolt EV’s electric motor with an offset gear and shaft configuration tailored to meet efficiency and performance targets – most notably more than an estimated 200 miles of range. The motor is capable of producing up to 266 lb.-ft. (360 Nm) of torque and 200 hp (150 kW) of motoring power. Combined with a 7.05:1 final drive ratio, it helps propel the Bolt EV from 0-60 mph in less than seven seconds.

Power delivery is controlled by Chevrolet’s first Electronic Precision Shift system. This shift and park-by-wire system sends electronic signals to the Bolt EV’s drive unit to manage precise feel and delivery of power and torque, based on drive mode selection and accelerator inputs. A by-wire shifter requires less packaging space than a traditional mechanical shifter, resulting in more interior space and improved interior layout.

60 kWh Battery System
Having more than 1.3 billion miles of EV experience from the Chevrolet Volt helped Bolt EV battery engineers and strategic partner LG Electronics to develop an all-new cell and battery pack to offer more than an estimated 200 miles of range.

Battery system preliminary specifications include:

  • 60 kWh lithium-ion battery pack.
  • 288 lithium ion cells
  • Five sections
  • 10 modules
  • 96 cell groups – three cells per group
  • 960 lbs. (435 kg) total weight

    “You usually have a battery cell that delivers either the desired levels of energy or power, but not traditionally both. With this cell design and chemistry we were able to deliver a battery system with 160 kilowatts of peak power and 60 kilowatts hours of energy,” said Gregory Smith, Bolt EV battery pack engineering group manager.

    The battery uses active thermal conditioning, similar to the Chevrolet Volt, to keep the battery operating at its optimum temperature, which results in solid battery life performance. The Bolt EV battery will be covered by an 8-year/ 100,000 mile (whichever comes first) limited warranty.

    Inside the battery pack – which spans the entire floor, from the front foot well to back of the rear seat – is a new cell design and chemistry. The nickel-rich lithium-ion chemistry provides improved thermal operating performance over other chemistries, which requires a smaller active cooling system for more efficient packaging. The chemistry allows the Bolt EV to maintain peak performance in varying climates and driver demands.

    The cells are arranged in a “landscape” format and each measures in at only 3.9 ins. (100 mms) high and 13.1 ins. (338 mms) wide providing improved packaging underfloor. The lower profile cell design enabled the vehicle structure team to maximize interior space.

    The battery system is mated to a standard equipment 7.2 kW onboard charger for regular overnight charging from a 240-V wall box. A typical commute of 50 miles can be recharged in less than two hours. Bolt EV also features an optional DC Fast Charging system using the industry standard SAE Combo connector. Using DC Fast Charging, the Bolt EV battery can be charged up to 90 miles of range in 30 minutes. Outside temperatures may affect charging times.

    Regen System Provides One-Pedal Driving
    Regenerative braking has become more than just a tool to boost range, it’s also transformed into a feature that can provide an improved EV driving experience. The Bolt EV features a new regenerative braking system that has the ability to provide one pedal driving.

    “Interviews with EV enthusiasts indicated their desire for one pedal driving capability on the Bolt EV. One pedal operation boosts the thrill and uniqueness of EV driving,” Tavel said.

    Through a combination of increased regenerative deceleration and software controls, one pedal driving enables the vehicle to slow down and come to a complete stop without using the brake pedal in certain driving conditions.

    When operating the Bolt EV in “Low” mode, or by holding the Regen on Demand paddle located on the back of the steering wheel, the driver can bring the vehicle to a complete stop under most circumstances by simply lifting their foot off the accelerator, although the system does not relieve the need to use the brake pedal altogether.

    Operating the Bolt EV in “Drive” mode and not pulling the paddle while decelerating delivers a driving experience where usage of the brake pedal is required to stop.

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    Daimler to invest 500 million Euros in new battery factory in Germany

    Daimler will invest 500 million Euros in a new battery factory in Germany. The new battery factory will produce lithium-ion battery packs for hybrid and electric vehicles for Mercedes-Benz and smart brands.

    Li-Tec, a subsidiary of the Daimler Group, ceased manufacture of battery cells in December 2015. The majority of the 280 employees were transferred to the Deutsche Accumotive—also a wholly owned Daimler subsidiary—which manufactures battery packs based on LG Chem cells.

    Daimler consistently expands its activities in the area of electromobility and invests around 500 million Euros in the construction of a new battery factory. This will lead to a significant expansion of the production capacities for lithium-ion batteries of Deutsche ACCUMOTIVE located in the Saxon city of Kamenz.

    The new factory will produce batteries for electric and hybrid vehicles of the brands Mercedes-Benz and smart. As a first step, the full Daimler subsidiary has purchased about 20 hectares of land adjacent to the existing battery factory.

    "To get closer to fully electric driving, we keep investing big in the key component of emission-free vehicles: powerful batteries. We are now devoting another 500 million Euros to build a second battery factory in Germany. This underlines our commitment to the consistent expansion of electromobility", said Dr. Dieter Zetsche, Chairman of the Board of Management of Daimler AG and Head of Mercedes-Benz Cars.

    Daimler announced a initial 100 million euros investment to expand East German battery pack output in 2014.

    With the growing electrification of the automobile, the demand for highly efficient lithium-ion batteries is also rising steadily. Through its entry into the new business field with stationary battery storage for private and industrial applications, Deutsche ACCUMOTIVE will tap into additional growth opportunities.

    By the end of 2014, the Daimler subsidiary had already announced its plans for a significant increase in its production capacities and an investment of around 100 million Euros in the expansion of the existing battery factory. "With the purchase of the new land, our production area at the site will be tripled.

    The previous 20,000 square meters will be stocked up by an additional 40,000 square meters of production space. We will expand the production capacity consistently in the coming years", said Harald Kröger, Head of Development Electrics/Electronics and e-Drive Mercedes-Benz Cars.

    The groundbreaking ceremony for the new factory is planned for fall 2016. The topping-out ceremony will then follow in spring 2017. The new production plant is to start operations in summer 2017.

    Daimler entered into the business with stationary battery storage with Deutsche ACCUMOTIVE last year. The scalability of the systems enables the use of the lithium-ion batteries in big industry for network stabilization and smoothing of peak shaving for energy producers as well as private households, for example in conjunction with photovoltaic installations.

    Mercedes-Benz energy storage units for private households can already be ordered and will soon be installed at customers in collaboration with selected sales partners. In the area of industrial applications, around 29 megawatt will be connected to the network jointly with different partners.

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    Tesla Model X vs Model S P90D 1/4 Mile Drag Race [VIDEO]

    Watch the all new Tesla Model X P90D Ludicrous race the Model S also with Ludicrous in an all out drag racing shootout.

    The Model X P90D with the $10,000 Ludicrous Mode runs 11.61 @ 116 MPH in the 1/4 mile setting a new world record for the quickest production SUV/CUV. 0-60 MPH came up in just 3.1 seconds. The Model S ran 11.3-11.5 @ 116 MPH.

    Source: Dragtimes