According to research by UK independent energy regulator, Ofgem, almost one in four consumers plan to buy an electric vehicle (EV) or plug-in hybrid in the next five years. EVs are growing in popularity, but there are still adoption hurdles that must be overcome before the UK’s 2030 new internal combustion engine (ICE) ban. Here Stewart Goulding, managing director of precision drive system supplier EMS, explores the drive system technology that can help.
Every car on the road that is powered by electricity not fossil fuels can save around 1.5 million grams of carbon dioxide (CO2) over the course of a year. Britain’s transition to EVs is a vital step in the UK Government’s Net Zero Strategy, with a ban on new petrol and diesel cars coming in to place in 2030, and hybrids in 2035.
EVs have risen in popularity over the years, yet still make up just 365,000 of the over 30 million cars on UK roads. Many of Britain’s drivers remain hesitant to transition to EVs, concerned about new challenges around charging. However, advanced technology such as high performance drive systems are helping to alleviate some common worries.
Charging challenges
EVs require regular charging, whether it’s a full charge or top up charge, to keep the vehicle ready for everyday use. Therefore, any inconvenience around charging an EV can put off drivers, and technology that makes the process quicker and simpler will aid adoption.
For instance, micromotors are being used to electronically open an EV charging port at the touch of a button. This provides easy access for the driver, and allows the port to be securely locked to prevent physical damage or tampering of the internal components. In these applications where there is limited space, it’s best that design engineers select a bespoke drive system to maximise the performance that can be achieved.
Conquering cables
A major inconvenience of EV charging is bulky cables and plugs that can be an eyesore on streets and clutter garages. What’s more, EV charging cable theft is on the rise, with the perpetrators either scrapping the copper-containing cables in for cash or reselling them online. In fact, over two thirds of licence holders surveyed by the AA said damage or theft of charging cables is the biggest EV security concern.
In addition, while contactless induction charging does eliminate the need for cables, it comes with its own challenges. Induction charging involves inserting a transmitter coil into the ground, meaning the floor has to be opened up and refinished, often ending in a less aesthetic result.
The transmitter coil, which is connected to an electrical supply, then interacts with the receiver coil in the car to create a magnetic field that charges the vehicle. However, a significant portion of the power is lost during the process compared to a cable method, especially if the EV isn’t parked directly over the transmitter coil.
The contactless process is typically slow with an output of just three kilowatts (kW) in most cases. In a survey by used car marketplace developer Autolist, more than one in four respondents reported slow charging as one of their biggest reasons for not buying an EV.
Micromotors are helping power a new piece of technology that has the convenience of contactless charging, with the power transmission speed of cable charging. The small, sleek and flat charging structure can be fixed onto the floor and is just six centimetres (cm) high, providing an inconspicuous solution.
A robot arm powered by micromotors can extend from the structure to seek out its counterpart connection on the car’s underbody to form a physical charging link. To accurately find its target, the robot uses an ultrasonic system, and the connection is established in less than 15 seconds. The car doesn’t need to be parked exactly over the arm — in fact, it can be anywhere within a 50 by 50 cm radius and even at an angle.
At homes where a typical connection is 22 kilowatts, the charge can be completed in around four to five hours. However, the system can handle up to 100 kilowatts if available, which reduces charging time to just one hour.
Mighty motors
When opting for a micromotor for EV charging equipment, it’s important that automotive engineers choose a manufacturer that is renowned for high performance and consistency so that the technology operates efficiently and reliably. For instance, FAULHABER motors, of which EMS is the sole UK supplier, produces all of its products in a precision manufacturing process, and integrates design features at the forefront of motor engineering, such as external rotor technology.
The popularity of EVs is increasing, but adoption must accelerate before the UK Government’s 2030 ban on new ICEs comes into place. Fortunately, advancements in micromotor technology are helping alleviate drivers’ concerns over EVs, such as charging difficulties and performance issues ― helping to power the nation’s transition to greener road travel.
