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Come to the Open Tech Forum for interactive presentations that include product teardowns, demos, and discussions of applications and trends.

Check out Munro & Associate’s teardown comparing motors from a Tesla Model 3 and a Jaguar I-PACE, learn how battery technology helped make the Apollo 11 moon landing possible, and take a test ride in the X PRIZE vehicle, Seven.

Sponsored by MEDC

This presentation will explore the opportunities and challenges of lithium-ion battery recycling. With the development of megafactories for lithium-ion batteries, there is a need to recycle these batteries at a “mega” scale. Li-Cycle Technology™ meets this need. Li-Cycle Technology is a low cost, safe, and environmentally friendly solution to the global end-of-life lithium-ion battery problem. The technology can recycle all types of lithium-ion batteries with unparalleled recoveries of 80 – 100%.

China is a perennial leader in the battery industry. There is a dramatic increase in Chinese patent filings and changes in Chinese patent laws, laying a foundation for increased protection of innovation around electrification. Software patents are now permitted in China. Specialized IP courts have been established in a number of Chinese cities. Meaningful enforcement of patents in China is on the rise. Punitive damages, for example, are now available and have been awarded. Old assumptions are fading and a new world order is emerging. It promises to be meaningful for those who wish to compete in the global battery marketplace.

Within the last two decades, the lithium market has seen enormous spurs in growth due to the utilization of the lithium-ion battery. Driven by the rise of electric vehicles (EVs) and new methods of energy storage, this demand shows no signs of slowing within the near future, prompting questions of the current markets supply capacity to fuel it. An understanding of the future of lithium is crucial for anyone looking to invest in the industry. This presentation examines which financial aspects will determine a project’s viability and allow an anticipation of future production success. In doing so, it provides an overview of the current geopolitical state of the lithium market and an outlook into how the future of the lithium market will develop.

Design News Senior Editor Dr. Kevin Clemens will look back at the first moon landing with Apollo 11 and the battery technology that made it all possible. He’ll also talk about how those same batteries from the lunar lander helped bring the Apollo 13 crew home after a fuel cell exploded during their trip to the moon.

All EV electronics — from batteries and electric motors to lighting and ECUs — are protected by enclosures. Inside these spaces, heat and pressure can build up quickly as exterior temperatures and elevations change in normal vehicle operation. Unless the enclosure is properly vented, differential pressure can cause gaskets to fail, deform the enclosure, allow the ingress of water, and ultimately lead to component malfunction. The most common materials for venting sealed electronic enclosures are expanded PTFE membranes, which keep out liquid and solid contaminants while allowing heat and pressure to escape. Because the membrane is delicate compared to the harsh automotive environment, it must be sized and attached to prevent damage from flying rocks, abrasion, and mechanical anomalies. Integration of the venting membrane into battery housing is a critical design consideration that has a direct impact on vent integrity and manufacturing costs. Jake Sanders (BSME, MBA) Product Development Manager of Venting Solutions at Donaldson Company, Inc., will outline the pros and cons of major vent integration methods and discuss factors that determine an optimal strategy. Participants will learn the keys to effectively using PTFE membrane in automotive and EV applications to produce longer-lasting battery enclosures, prolong battery life cycles, and improve passenger and bystander safety.

Battery management systems are designed to prevent the conditions for cell failure, which may lead to a thermal event occurring. Yet such events still occur from time to time. If a cell failure occurs, what role can the BMS play in preventing thermal runaway? The key challenges will be identified, along with considerations for paths to mitigation.

As the world becomes more conscious about its carbon footprint and pollution, an increasing number of machines are replacing internal combustion engines with electric systems. This phenomenon is increasing demand for lithium-ion batteries with long life expectancies.

Did you know the battery charger you choose significantly affects the quality of your machine?

Selecting the right lithium-ion battery charger is important to ensure your machine is efficiently and accurately charged. Alternatively, picking a low-quality charger can reduce the life span of lithium-ion batteries, damage vehicle performance, and increase total cost of ownership.

In this presentation, Delta-Q Technologies will discuss:

  • The importance of battery charger selection for lithium battery system performance
  • • How to create an efficient charging system that complies with global regulations
  • • Tips on system integration to reduce total cost of ownership

The purpose of RISE is to accelerate the electrification of heavy machinery. RISE will be presenting on stage a new mechanical motion technology which is a new type of linear actuator that replaces whole hydraulic cylinder systems. This new mechanical motion technology is called RISE™Cylinder and it provides motor-to-movement solutions from subsea to space. High performance belts and pulleys are compacted inside each RISE Cylinder, eliminating fluids, doubling runtime, halving fuel consumption, and charging batteries with hybrid regeneration. RISE Cylinder delivers hydraulic-like performance in a simple, maintenance-free and fluid-free package. RISE’s new high-efficiency, long-lasting drive solutions allow for the electrification of machinery in a wide range of applications. We are always expanding our offerings and are currently seeking meetings with leadership at companies who want a competitive advantage in the following industries; agricultural equipment, airport support vehicles, emergency vehicles, forestry equipment, heavy construction, material handling equipment, marine applications, mining equipment, multi-stop delivery vehicles, railroad equipment, recreation vehicles, service and utility vehicles, crane/swing boom equipment, waste and recycling vehicles and transit. Ready to bring the next big innovation in electrification to your company? RISE is currently seeking meetings with leadership at machinery companies who want a competitive advantage.

The automotive industry is being subjected to unprecedented legislative, technological and societal change. Rising levels of road congestion and transport-related air pollution have led local and national legislators to introduce exacting regulations that will dramatically reduce the number of internal combustion engines within the next 15 to 20 years. Disruptive technology is already breaking down barriers to the roll-out of electrified vehicles, while connectivity and the development of autonomous technologies promises to bring new ways to move people and goods. This new era of mobility offers opportunities for brands able to embrace the changes and answer the demand for new solutions, services and revenue streams. Forecasts suggest the global intelligent mobility market will be worth over $1tn per annum by 2025. For a wide range of applications, familiar electrified powertrain layouts (for hybrid, plug-in hybrid and “pure” electric vehicles) result in compromises when it comes to design and packaging. In-wheel motors offer all of the benefits of electric propulsion, but also enable much greater freedom in the design and configuration of vehicle interiors thanks to the absence of a motor, axles, differentials, driveshafts, and constant velocity joints within the vehicle body.

Electric motors, as found in hybrid and electric vehicles, lack an idle state or engine start-stop. They weigh less and show considerably higher excitation frequencies while enduring high torques and rapid torque changes during acceleration and recuperation.

E-motor mounting systems often consist of 3 or 4 bushings. A proper system layout and component level innovations are needed to handle the e-motor’s high frequency excitations. Vibracoustic, as a leading global supplier of automotive NVH solutions, can offer several such technologies.

QuietType® bushings, flap bushings and double isolation are presented to elevate motor mounting system isolation in different, though partly overlapping, frequency ranges.

QuietType bushings use the specific design of a continuum-mechanical effect to achieve a significantly reduced dynamic stiffness across a broad and configurable frequency range.

Flap bushings on the other hand use additional surface features on the rubber to create a tailored mass absorber effect, thus improving the higher frequency isolation without impacting the bushing’s baseline properties. A virtual development process is applied to design and predict such mounts rapidly and accurately.

Double isolation, on mount or system level, can be combined with the aforementioned solutions.

All these solutions contribute to a better acoustic comfort in the vehicle cabin.

How inverters based on discrete packages benefit from using sintered silver to replace solder for the package to substrate attachment. New test data will compare and quantify the performance difference using silver sinter materials compared to solder for package attach of discrete components in power switching applications, such as Inverters and on-board chargers.

A short overview of electric vehicle efficiency as it pertains to existing high efficiency street legal vehicles and how to apply these technologies to other EVs. Followed by the results of experiments over the past year to apply these and other technologies to the X PRIZE vehicle, Seven. Accompanied, outside, by live demonstrations and rides in Seven.

Munro & Associates will display two completely disassembled electric motors; one Tesla Model 3 internal permanent magnet (IPM) and one Jaguar I-PACE IPM. The intent of the 25-minute forum is to dive into the key differences between the executions of the IPM motor designs. Munro will highlight the key differences in the geometry of the rotor and stator, the placement and retention of the magnets, and specific details about the magnet material compositions and manufacturing processes. Come with detailed questions concerning the skew angles, fill rates, and material compositions of the various rotor and stator parts components.

Solid-state battery is a battery technology that uses both solid electrodes and solid electrolytes, instead of the liquid or polymer electrolytes found in lithium-ion or lithium polymer batteries. The technology is a proposed alternative to conventional lithium-ion battery technology. Solid-state battery technology is also believed to allow for faster recharging for electric cars, in addition, higher voltage and longer cycle life is possible with solid-state batteries. Meanwhile, mass production and integration paradigm of innovative battery system are discussed. Vital parameters such as material cost, cell lifetime, energy performance and operating capabilities collectively contribute to desired SSN output. Several research vectors for advancing commercialization of SSN are highlighted including scalable manufacturing of low defect density thin ionic conducting solids, characterization methods to determine defect densities, protective active cathode particle coatings. Furthermore, mechanical integration of fuel cell structures requires different strategies regarding cell performance and attributes. From R&D to adoption to public, risk mitigation strategies such as smart battery management systems and software must be readily developed to optimize in electrochemical and energy efficient manner. Finally, multiple levels of failure modes due to phenomena at the solid electrolyte-electrode interface are to be identified and addressed in holistic consideration.

High penetration renewable microgrids can reduce costs and increase resiliency in both islanded and grid-connected microgrids. Combining solar with battery energy storage can augment existing diesel-only microgrids to provide clean, reliable power in the developing world. In this talk, we will discuss how we use life cycle cost analysis techniques to build the bankable business case for high penetration renewable microgrids featuring solar and storage. We’ll show how we use our Redcloud energy optimization platform to integrate data such as load profiles, solar resource, prevailing rate and fuel prices, and economic projections to help developers, financiers, and component manufacturers rank and prioritize sites for further study and investment. We’ll present our design and analysis for a 200 kW off-grid microgrid comprised of solar, battery storage, and diesel generation at a remote facility in Latin America.

Presenting a series of sessions organized by the Michigan Economic Development Corporation’s Automotive Office, learn about the exciting work being done in Michigan on battery and electric and hybrid vehicle technologies.