EV, Battery & Charging News: BorgWarner, CATL, ZF, Renault, VW, Sensata Tech,

In electric vehicle, battery and charging news are BorgWarner, CATL, ZF Renault, VW, Sensata and Tech.

BorgWarner Grant and New HVCH

BorgWarner Thermal Systems has been awarded a grant to grow its electric vehicle business and is set to launch a new high-voltage coolant heater (HVCH) at its existing facility in Cadillac, Michigan. The electrification project is expected to generate a total capital investment of $11.2 million and create up to 30 jobs with support from the city of Cadillac in addition to a $225,000 Michigan Business Development Program performance-based grant through the Michigan Economic Development Corporation (MEDC).

BorgWarner Cadillac will manufacture advanced HVCH systems that will be used to manage cabin and battery temperatures, critical for vehicle efficiency in hybrid and pure electric vehicles.

CATL Partners with ZF

On November 19, Contemporary Amperex Technology Co., Limited (CATL) and ZF Group signed a global strategic partnership agreement to push forward cooperation in aftermarket services, including service network, battery-related training, connectivity, recycling and reuse, etc. ZF and CATL intend to facilitate mutual transfer of knowledge and expertise, according to the agreement, to enable a sustainable ecosystem and with that an attractive mobility experience for everyone.

CATL, a global leader in new energy technologies, will enhance its global aftersales capabilities and efficiency with this collaboration. ZF with more than 10,000 workshop partners in its global aftermarket and with the growing products for electric vehicles in OEM quality, will be considered the preferred option in CATL’s service network expansion. Under the agreement, CATL will provide ZF with comprehensive battery training know-how, which will be combined with ZF’s DGUV high voltage training to further enhance the competitiveness of its training programs and other aftersales services.

The two parties also agree to jointly establish and uplift standards to be the benchmark for the industry.

With the common vision and mission on sustainability, ZF Group and CATL also agreed to cooperate on data connectivity and recycling resp. reuse.

“Enabling creative collaboration between companies can jump-start business innovation. We are proud to be able to complement our aftermarket competencies with those of one of the world’s leaders in new energy. Together with CATL we will bring the global footprint and leading service solutions of ZF’s Aftermarket Division further into play,” said Dr. Holger Klein, member of the Board of Management, ZF Group. “We want to drive growth which regenerates and actually improves our natural world. ZF is pursuing corporate responsibility in green energy and low carbon outlay and is committed to realizing the future vision of ‘zero emission and zero accident’.”

“The partnership with ZF is an important step towards developing a global comprehensive value chain of batteries. With the support of ZF’s worldwide network, we will further enhance our global aftermarket service and continue to deliver customer-driven new energy products to the world,” said Zhou Jia, CEO of CATL. “Together with ZF, we are also confident that we can contribute to the global trend towards e-mobility and net zero emissions.”

It is the strong conviction of both companies – ZF Group and CATL – to play a leading role in shaping the next generation mobility, not only through technical innovations, but also through leading aftermarket services. The promising start of the new strategic partnership proves that, together you can find more efficiently convincing answers to the challenges of transformation.

Renault Gets Solar Polar from MiaSolé Hi-Tech Corp.

– SOLUTRANS is a biennial trade fair where innovation and information comes together at Lyon Eurexpo for the Heavy Goods Vehicles (HGV) industry. This year, Renault Trucks, a French commercial truck manufacturer, is incorporating world leading stainless steel-based CIGS flexible shatterproof photovoltaic technology from the solar sails of numerous American boats into the roofs of their trucks. Come join us at Booth 4D 104 from November 16-20 at SOLUTRANS!

Renault’s PV Roof Wind Deflector comes with a host of benefits:

300W electricity generation in an ultra thin package proven to be reliable in extreme weather and road conditions.
Allows the truck to sustain the growing need for electricity on board: microwaves, tablets, kettles, refrigerators, etc.
Increases battery life
Charges the battery even when the vehicle motor is not running
Can prevent empty battery troubleshooting

The original solar sail technology was developed through a collaboration between France-based SolarCloth and California-based MiaSolé Hi-Tech Corp.

GenCell Partners with E.V. Motors

GenCell Energy, (TASE: GNCL), a leading Israel-based manufacturer of fuel cell energy solutions announces that it has signed an agreement with E.V. Motors Ltd., an Israeli importer of electric vehicles, chargers and energy storage systems for electric vehicles and the exclusive Israeli representative of several companies, among them Sun Surplus Energy and Co. Ltd., a leading developer of energy storage and advanced EV charging systems.  The two companies have agreed to cooperate on the development of a joint project integrating GenCell’s alkaline fuel cells together with E.V. Motors’ electric vehicle charging technologies to enable autonomous off-grid hybrid electric vehicle charging stations that eliminate the need for fossil fuel backup generators.   The project will provide demonstration sites that are expected to attract interest from e-mobility companies worldwide.

This collaboration will contribute to the worldwide delivery of the charging infrastructure required to meet the global EV charging market demand, which is expected to exceed US$207bn by 2030. * GenCell and EV Motors will create a new off-grid hybrid charging solution that will provide reliable local power supplies with zero emissions. The joint system is expected to be ready for initial deployment in Israel by the first half of 2022. Following the success of the initial project in Israel, the two companies will consider expanding the cooperation to similar projects in China and other territories via EV’s existing partner network including Sun Surplus Energy and Co Ltd.

EV Connect Connects with GM Dealers

Premier electric vehicle (EV) charging solution provider EV Connect announced that the Company is one of the approved EV Charging solutions providers to support the deployment of charging at General Motors’ dealerships (NYSE: GM) across the U.S and Canada. As an approved platform to support GM’s EV dealerships, EV Connect will offer its innovative EV charging management solutions that include advanced data analytics and 24/7 customer support. The first charging stations under the new program have been installed at select GM dealers, with more installations occurring this year.

Through EV Connect’s open charging cloud platform, GM dealerships will have the ability to optimize charging solutions at their stores to meet individual dealership needs. EV Connect will also provide comprehensive training for the software management platform for all participating dealerships to ensure a simple, reliable, and manageable charging experience.

“With thirty new EV models coming to market globally by 2025, we are committed to bringing robust EV solutions by providing reliable EV charging for drivers and service departments,” said Hossein Hassani, director, EV Ecosystem at GM. “To do this, our dealerships need to be equipped with reliable, efficient, and simple-to-use EV charging infrastructure. We are excited to work with EV Connect for core management software  as we continue to help expand access to charging at GM brand dealerships and beyond.”

By leveraging the Company’s vast experience in guiding companies of all sizes in managing charging networks and delivering a seamless EV charging experience, EV Connect has established a playbook for managing and growing the entire EV ecosystem. EV Connect offers GM dealerships a powerful software management platform that connects dealerships to their hardware, and also enables dealers the ability to control access, set pricing and make reservations as well as load management tools to control energy costs.

“As GM actively prepares its dealerships for their forthcoming EV models, we are excited to help bring flexibility and scalability to EV charging for GM dealers today,” said Jordan Ramer, Co-founder and Chief Executive Officer of EV Connect. “Already in short order, we have more than 500 dealerships signed up for the program that are looking to electrify. We are excited to see this number grow as we help GM work towards an all-electric future.”

EV Connect has also joined Ultium Charge 360, GM’s holistic approach to charging that integrates GM mobile apps, charging networks, services and products to deliver the best charging experience for GM EV owners. Drivers of Chevrolet, Cadillac, and GMC EVs will now be able to find 5,000 EV Connect public chargers through the myChevrolet, myGMC, and myCadillac mobile apps as well as conveniently locate a station, check station status, and start a charge. Ultium Charge 360 gives GM EV drivers access to real-time information for more than 85,000 public chargers throughout the U.S. and Canada.

Lightning eMotors Provide Electric Vans to RideCo for LA Metro

-Lightning eMotors (NYSE: ZEV), a leading provider of all-electric powertrains and medium-duty and specialty commercial electric fleet vehicles, announced an agreement with on-demand transit industry leader RideCo to provide zero-emission passenger vans for the Los Angeles County Metropolitan Transportation Authority (Metro).

Under the agreement, Lightning eMotors will serve as the preferred zero-emission vehicle vendor for RideCo as it manages a fleet of vehicles for Metro Micro, a pilot program designed to provide fast and convenient rides within the service zones in Los Angeles County. Lightning eMotors will initially supply RideCo with 10 all-electric passenger vans. Several of those vehicles have already been delivered, and RideCo anticipates that all 10 will be transporting passengers around Los Angeles County by early next year.

“From the outset, our goal was to introduce zero-emission vehicles into our fleet. After evaluating several potential vendors, Lightning eMotors emerged as a clear choice,” said RideCo CEO Prem Gururajan. “We are excited to work with Lightning eMotors to deliver this innovative microtransit service in Los Angeles County.”

“Metro is one of the largest and most sophisticated transportation agencies in the nation. We are proud to provide these vans to RideCo as part of Metro’s long-term goals to transition to zero-emission transit vehicles,” said Lightning eMotors CEO Tim Reeser. “We are also grateful to RideCo, an industry leader and pioneer in on-demand transit technology and ridesharing for the public, for selecting Lightning eMotors as its preferred vendor.”

In December 2020, Metro launched Metro Micro – a state-of-the-art 100-vehicle on-demand microtransit service – to connect Angelenos in outlying areas and traditionally underserved communities with existing fixed-route bus and train network as well as accommodate short trips in the service zones. This project is currently piloting in seven zones across Los Angeles County, with one more service zone planned in December 2021.

Lightning eMotors’ vans are designed with 86 kWh of battery capacity which can transport nine passengers and the driver with plenty of cargo space for a range of approximately 120 miles. Additionally, Lightning eMotors is providing the charging infrastructure to support the test fleet via its Lightning Energy division.

Eli Charges at Better Rates for VW

— Elli, the Volkswagen subsidiary that provides sustainable energy and charging solutions, has partnered with ev.energy to launch the Volkswagen Group’s first ever intelligent household electricity tariff: Volkswagen Naturstrom Connect.  The tariff will use ev.energy’s platform to market and manage the new tariff with electric vehicle owners.

The Volkswagen Naturstrom Connect tariff has been developed by directly integrating the energy tariff with electric vehicle charging usage, controlled through the Naturstrom Connect app. The customer allows their electric vehicle charging to dynamically respond to the carbon intensity on the grid and in exchange, they will generate one reward point for every qualifying smart charge over 7kWh. For every 10 points generated, the customer will receive a 5€ bill credit which is then credited to their annual electricity bill. The customer can save up to 100€ per year and will be able to track their energy use, carbon avoidance and energy cost-savings over time.

Through the app and connected customer experience, Elli and ev.energy have created a scalable eco-system that reduces cost for electric vehicle owners through their EV adoption, while satisfying the long-term goals of sustainable, zero-carbon energy for the masses. With this offering, Elli and the Naturstrom Connect tariff has gained TÜV Rheinland accreditation.

The Volkswagen Naturstrom Connect app will integrate directly with Volkswagen vehicles through an owner’s Volkswagen ID, enabling a seamless login and connected mobility experience.

Elli selected ev.energy to deliver this proposition over a multi-year contract after working with them during the Volkswagen Future Mobility Incubator.

Johannes Rönsberg, Coordinator Volkswagen Future Mobility Incubator mentioned: “It’s great to see ev.energy come through the program and get commercial traction to the Elli team so quickly. This is a great testament to Volkswagen’s approach of bringing great start-ups through our programs, and launching the best ideas in the market.”

Ingo Müller, Head of Energy Solutions of Elli, highlights: “The new Volkswagen Naturstrom Connect tariff allows our customers to take the next step on the path to a sustainable mobility. We are happy to offer a solution that not only reduces the carbon footprint but also the electricity bill of our customers. Together with our partner ev.energy, we are planning to make this service/tariff available to many more EV drivers in the future.”

Nick Woolley, Co-founder and CEO of ev.energy, said: “This is a major milestone not only for us and for Volkswagen, but more importantly for EV drivers, by integrating smart charging into home charging and energy services. I’m excited to be scaling a first of a kind tariff in Volkswagen’s home country, and beyond. It’s been fantastic working so closely with the Elli and wider Volkswagen Group Charging team to develop a solution that is greener, cheaper and simpler for EV drivers.”

Nexar Digital Twins of US

Nexar uses the footage it collects to create an AI-digital twin of U.S. roads and their surroundings. This dynamic representation provides real-time updates in a range of key areas such as work zones, road signs, road markings, potholes & many other elements, for a constant stream of accurate information. With this tool, city officials are able to plan, prioritize and fix issues at a much faster pace, while automotive companies are able to inform their autonomous vehicles of obstacles lying ahead.

Sensata i-BMS BMS

Sensata Technologies announced the availability of its new i-BMS battery management system (BMS) for electrified applications up to 60V.

The new i-BMS Battery Management System from Sensata’s Lithium Balance product brand, acquired by Sensata earlier in the year, is a cell chemistry agnostic, compact, integrated BMS developed for the cost-optimized mass-production of applications up to 60V, such as 2-, and 3-wheelers, automated guided vehicles (AGVs), and robotics.

Hot swap functionality and parallel battery pack support allow for the ability to quickly exchange depleted batteries with fully charged batteries. For example, for material handling vehicles, delivery vehicles and drones, when returning to base to pick up a new load, the vehicle’s depleted batteries can be quickly swapped for charged ones, allowing for continuous uptime. For electric motorbikes and three wheelers, instead of needing to recharge for several hours every evening, fully charged batteries can be rapidly installed in the field at battery swap stations, practically eliminating the need to wait and charge on the road and helping alleviate end-user’s concerns around charging time.

Parallel pack support allows the use of two or more battery packs in parallel. This functionality allows OEMs of 2- and 3-wheelers to have smaller battery modules, improving the safety and serviceability of the battery system. For example, if one battery cell fails while in use, the issue is isolated to that one faulty module which is easier to replace than the entire system and additional battery packs can continue to provide power.

While measuring only 65 x 200 mm (2.6 x 7.9 in), the i-BMS PCB board is equipped with everything required to manage and maintain a battery system without the need for any external components, making it a convenient and cost-efficient design for mass production. All critical components are pre-integrated into the system, including a pre-charge circuit, on-board current measurement, MOSFET power switches for battery disconnect, and a DC/DC power supply. The solution features key components that are ASIL C Safety rated and include self-test capabilities for safety critical measurement circuits.

The advanced algorithms in Sensata’s BMS software ensure accurate state-of-power (SOP) predictions based on cell internal resistance, voltage and current constraints, precise state-of-charge (SOC) calculations, and (state-of-health) SOH calculated based on aging effect.

The high degree of accuracy in assessing the state of the battery allows for a more precise battery system, helping customers maximize utilization of the battery, and increase range, uptime and performance of the vehicle. In addition, the BMS Creator™ configuration software allows the battery pack designer to create a unique battery setup by defining application-specific BMS parameters and safety strategies, optimizing battery operation.

Other advanced software features include measurement of rate of change of temperature to predict thermal runaway, dynamical regulation of current in extreme thermal conditions, as well as advanced parameter settings for CAN communication.

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