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Evans Electric Unveils AWD In-Wheel Motor powered electric car

Australia based start-up company Evans Electric have unveiled an All Wheel Drive In-Wheel Motor powered Lancer Evo 3 during Meguiar's MotorEx at Sydney Olympic Park

The 4 door sedan with World Rally Championship pedigree features a direct drive, disc type electric motor in each of it's 19” wheels. Each Axial Flux 3 phase AC Induction wheel motor has a nominal output of 75 kw and 625 Nm of torque with a peak output of 150 kw and 1,250 Nm giving the vehicle a total peak output of 600 kw (800 hp) and 5,000 Nm.

While the torque figure could at first glance appear fantastic, standard automotive industry practice only quotes torque at the flywheel not at the wheels. As an example the Tesla Model S Performance has a quoted peak motor torque of 600 Nm. With a single speed reduction gear ratio of 9.73:1 that equates to a total of 5,838 Nm (minus gearing losses) at the wheels. The Evans Electric motors are direct drive, so the rotor turns at the same speed as the wheel. Instead of mechanical reduction gearing, they are electrically geared using an 8 pole stator winding configuration.

Direct drive wheel motors eliminate mechanical transmission losses allowing up to 85% of a vehicle's kinetic energy to be recoverable during braking. Maximising brake regeneration lowers a vehicles over-all energy consumption potentially leading to more range per kWh of battery capacity or the use of a smaller battery pack for similar range. As the battery is the single most expensive component in an EV this could lead to lower cost electric cars.

The Evans Electric in-wheel motors enable non-contact electromagnetic braking, replacing hydraulic friction brake systems which are 99% redundant in current generation electric/hybrid vehicles. Using only the wheel motors, the car can brake at greater than 1G.

Evans Electric hold a patent for a vehicle drive system using wheel motors for propulsion and braking, the most impressive feature of which is that safety and vehicle dynamics features such as ABS, stability control, traction control, brake steer, active brake bias, torque vectoring, intelligent cruise control, emergency brake assist and collision avoidance all become customisable and upgradable software functions.

When these systems are combined with wheel motors they allow a new level of performance based active yaw control that unlike most current stability control systems (which only activate in an emergency situation) are active at all times, dynamically fine tuning understeer and oversteer to enhance cornering speed and safety.

After an extensive period of wheel motor validation testing and power electronics development the company has met with several automotive Tier 1 suppliers to discuss collaboration &/or licensing to move the project from proof of concept to commercial product development.

Final preparations are under way with track testing expected to commence by the time the Bathurst 1000 rolls around in October.

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Cadillac ELR Goes Ultrasonic in Pursuit of High Quality

Ultrasonic welding, a high-tech manufacturing process used in the aerospace and medical industries, is helping ensure high quality for the new Cadillac ELR extended-range electric luxury coupe that goes on sale in North America in early 2014.

Ultrasonic welding’s key advantage is exceptional and predictable quality and performance from one battery pack to the next. Every ELR battery, for example, has close to 200 ultrasonic welds. Each is required to meet stringent quality requirements, enabling Cadillac to offer an eight-year/100,000-mile battery system warranty.

Short cycle times, low capital costs and manufacturing flexibility through the use of automation are other advantages of ultrasonic welding.

“Ultrasonic welding is a far superior joining technology in applications where it can be deployed,” said Jay Baron, president and CEO of the Center for Automotive Research in Ann Arbor, Mich. “Cadillac’s innovative process will produce batteries with superior quality compared with traditional methods – and do it more efficiently. This is one example of technology development that is becoming pervasive in today’s world class vehicles.”

General Motors’ Brownstown Battery Assembly plant near Detroit, uses ultrasonic welding to join metal electrode tabs on ELR’s advanced 16.5-kWh lithium-ion battery system, and does it with a proprietary quality monitoring process. Brownstown uses an automated system to execute millions of these welds each year.

Ultrasonic welding uses specialized tools called an anvil and horn to apply rapid mechanical vibrations to the battery’s copper and aluminum electrodes. This creates heat through friction, resulting in a weld that does not require melting-point temperatures or joining material such as adhesives, soldering or fasteners.

An integrated camera vision system is used to shoot a reference image of the weld area prior to the operation to achieve pinpoint accuracy. Quality operators check electrode tabs before and after welding, and the system monitors dozens of signal processing features during each weld.

The battery-specific welding process is a result of collaboration among General Motors’ Manufacturing Systems Research Lab and Advanced Propulsion Center and the Brownstown plant. GM first applied the process on the award-winning Chevrolet Volt – its groundbreaking extended-range electric vehicle – and further refined it for ELR.

“This effort is an outstanding example of teamwork between research and manufacturing engineering,” said Catherine Clegg, GM vice president of Global Manufacturing Engineering. “It has helped integrate the use of highly technical, complex technology into a sustainable manufacturing process, which means we can consistently deliver high-quality batteries to our customers for the Cadillac ELR.”

The ELR’s T-shaped battery pack is located along the centerline of the vehicle, between the front and rear wheels for optimal weight distribution. The 5.5-foot-long (1.6 m), 435-pound (198 kg) pack supplies energy to an advanced electric drive unit capable of 295 lb-ft of instant torque (400 Nm) to propel the vehicle. Using only the energy stored in the battery, the ELR will deliver a GM-estimated range of about 35 miles (56 km) of pure electric driving, depending on terrain, driving techniques and temperature.

Charging the ELR’s battery can be done with a 120V electrical outlet or a dedicated 240V charging station. The vehicle can be completely recharged in about 4.5 hours using a 240V outlet, depending on the outside temperature.

The Cadillac ELR is built at GM’s Detroit-Hamtramck Assembly Plant, one of the few high-volume electric vehicle manufacturing facilities based in the U.S. Its battery pack is built from cell to pack at Brownstown and shipped to Detroit-Hamtramck for assembly into the vehicle.

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Spark-Renault SRT_01E Formula E race car to debut in Frankfurt

Spark Racing Technology has announced plans to introduce their Spark-Renault SRT_01E Formula E race car at the Frankfurt Motor Show on September 10th.

Set to become one the most prominent race cars in the series, the SRT_01E has a Dallara-designed monocoque chassis that is constructed out of carbon fiber and aluminum. The model also features aerodynamic styling and bespoke Michelin tires that are specifically designed to last the entire race.

While the McLaren-sourced electric powertrain can produce up to 270 bhp (200 kW), it will be limited to 180 bhp (133 kW) during races. However, drivers can use a 'Push-to-Pass' system which temporary allows the car to harness its full potential. This should enable the model to accelerate from 0-100 km/h in approximately three seconds and hit an FIA-limited top speed of 225 km/h (140 mph).

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LG Chem Michigan begin Chevy Volt battery production

The US subsidiary of South Korean company LG Chem last month began producing batteries for the Chevrolet Volt at its Holland-area facility.

LG Chem spokesman Randy Boileau says employees completed “pre-production testing” with General Motors Co. and began ramping up production in July. He says LG Chem anticipates the first shipments from the facility will come in September or October.

LG Chem drew attention during its 2010 groundbreaking, when President Barack Obama traveled to Michigan for the event.

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Nissan and Ecotricity to further expand UK motorway charging network

Electric vehicle drivers using the UK’s motorway system can now access 13 more rapid chargers at Welcome Break service stations.

Installed at Welcome Break sites across the country, the 13 rapid chargers represent the latest phase of work completed by Nissan and Ecotricity to expand the rapid charging network on the UK’s motorways.

Taking into account the existing infrastructure installed under the partnership earlier this year, there are now 16 rapid chargers available at Welcome Break service stations on the motorway, with plans to install at the majority of Welcome Break sites by April 2014.

The new additions mean the total number of rapid chargers in the UK is now 97.

The chargers form the UK’s first publicly accessible rapid charging network on the motorway and are capable of ‘refuelling’ an all-electric Nissan LEAF from 0 to 80 per cent battery capacity in just 30 minutes. Safe in the knowledge that there are Welcome Break service stations up and down the country equipped with rapid charging technology, EV users can now explore opportunities to take longer journeys using the UK’s motorway system.

Jim Wright, managing director of Nissan GB, said:“Nissan is working hard to ensure that 100% electric driving becomes accessible for all UK motorists and the installation of a rapid charging network on the motorway opens up EV ownership to thousands more motorists.

“The UK’s charging landscape is improving daily, and we are very proud to be the main power source driving the development of infrastructure that will ultimately provide further flexibility and peace of mind to our LEAF drivers.”

Ecotricity founder, Dale Vince added: “The main barrier in people’s mind to the take up of electric cars is their travel range and charging times.

“Really these issues are one and the same. Concern over the distance that an electric car will travel on a single charge, called range anxiety, can be overcome if you have the right charging infrastructure in the right locations – to quickly recharge.”

Nissan is leading the way in developing electric vehicle charging infrastructure, and the new rapid charging network at Welcome Break service stations is part of a long-term plan to install more than 150 rapid chargers across the UK by April 2014. Since 2011, 97 rapid chargers have been installed across the UK with Nissan as the driving force.

In July, Nissan launched the next generation LEAF, packed with over 100 improvements including increased driving range and quicker charging times. Keen to give motorists maximum choice, Nissan offers the model in three distinctive trim levels as well as a variety of flexible finance packages such as a battery leasingoption.

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A Hankering for Hybrids

About 298,000 hybrids, or cars that run on batteries and gasoline, have been sold this year while only 36,000 battery-powered vehicles have sold.
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Panasonic to make more lithium-ion batteries to meet robust US automotive demand

Panasonic will increase domestic production of lithium-ion battery used for automobiles to meet robust demand in the United States, company officials said on Thursday.

The electronics maker will resume operation of idled lines at the Suminoe Plant in Osaka Prefecture, which produces batteries for U.S. automaker Tesla Motors Inc., as early as next January, while another factory in Kaizuka City in the prefecture, which the company has suspended its operation since March, will reopen by the end of next fiscal year, Panasonic spokesperson Megumi Kitagawa said to Xinhua.

She also said that the company will add some manufacturing lines at the Kasai plant in Hyogo Prefecture, which produces batteries for domestic automakers, by the end of the current fiscal year through next March.

In June Panasonic announced that shipments of its automotive-grade lithium-ion battery cells for Tesla Motors’ premium, all-electric Model S sedan surpassed 100 million units.

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GoPro: Monster Tajima – Pikes Peak 2013 EV Class Winner [VIDEO]

Finally the GoPro video of the Pikes Peak EV class winning run is uploaded.

Nobuhiro 'Monster' Tajima returned to the 91st Pikes Peak International Hill Climb with his E-Runner Special electric car. Tajima was back and more determined than ever, not only to break his personal record (9:51.278 in 2011) but to make a statement that the electric car is a force to reckon with.

Tajima set a new personal record of 9:46.530, winning the Electric class and placing 5th overall.