Tech Blog
U.S. DOE reinforces its commitment to advanced batteries for EVs with new technology Hub
The U.S. Department of Energy on Nov. 30 announced it will establish a major advanced-battery research center on the campus of Argonne National Laboratory outside Chicago. The Batteries and Energy Storage Hub, also called the Joint Center for Energy Storage Research (JCESR). Establishment of the Hub is tied to the award of DOE funding of up to $120 million for a research team led by Argonne and consisting of additional national labs, universities, and private companies, the latter consisting of Dow Chemical Co., Applied Materials Inc., Johnson Controls Inc., and Clean Energy Trust. JCESR will integrate independent research being done by the participating entities into a coordinated effort. It is the fourth Hub established by the DOE since 2010 (the others address nuclear energy, building efficiency, and fuels derived from sunlight), and like the others it is modeled on the "strong scientific management characteristics of the Manhattan Project" and similarly renowned enterprises. Research will apply to multiple industries, not just automotive.
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Argonne scientist Ira Bloom examines a metallographic sample using an optical microscope to determine its microstructure in the laboratory's Battery Post-Test Facility. This information helps researchers learn what chemical and physical changes have occurred during the aging of battery materials.
Parker Aerospace, GE Aviation launch joint venture
Parker Aerospace and GE Aviation reached an agreement to form a joint venture, Advanced Atomization Technologies LLC, to enhance the development and manufacture of commercial aircraft engine fuel nozzles. This represents a critical addition to the comprehensive GE fuel management team. The 50:50 joint venture—created specifically to produce fuel nozzles for current and future GE Aviation commercial engine platforms (including aerospace and aero-derivative engines)—will be located in the Parker Gas Turbine Fuel Systems Division facility in Clyde, NY. The joint venture will employ approximately 300 skilled assemblers, technicians, engineers, and other professionals in the production of advanced fuel nozzles and related products for GE Aviation.
XCOR announces ATK as Lynx Mark I Wing detailed design/build contractor
XCOR Aerospace has issued the initial phase of a two-phase contract to ATK's Aerospace Structures Division for the detailed design and manufacture of the Lynx Mark I suborbital reusable launch vehicle (RLV) wings and control surfaces. The initial wing and control surface design has been developed by XCOR to rigorous design standards to enable the craft to perform tens of thousands of flights to and from suborbital altitudes exceeding 100 km. ATK will create a detailed design ready for manufacture, working with structural and flutter analysis experts from Quartus Engineering in San Diego, CA. The wings will be installed on the Lynx Mark I, which is the prototype of the Lynx family of suborbital RLVs from XCOR; the production models are called Lynx Mark II.
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Proposed detailed wing design for XCOR Lynx Mark I to be designed by ATK.
Dassault Falcon establishes Chinese subsidiary
Dassault Falcon has established a '"wholly owned foreign entity" to represent the Falcon brand in the growing Chinese market. The subsidiary, known as Dassault Falcon Business Services (Beijing) Co. Ltd., is based in Beijing, China. As part of the subsidiary, Dassault Falcon will establish a regional customer service headquarters in Beijing. Scheduled to start operations in early 2013, the office will be staffed by local specialists experienced in receiving and processing spare parts orders, warranty, and FalconCare claims. The office will also oversee four field technical representatives that are based in Greater China. Additionally, at least two type-rated Falcon pilots will be based in Beijing to provide jump-seat support to new and existing Falcon customers. Earlier this year, Dassault revealed that the number of Falcons operating in China will triple before the end of 2012.
GE Aviation acquires pair of precision manufacturing companies
GE Aviation has acquired the assets of Morris Technologies and its sister company, Rapid Quality Manufacturing, precision manufacturing companies operating in suburban Cincinnati, OH. The companies, with about 130 employees, specialize in additive manufacturing, an automated process for creating rapid prototypes and end-use production components. With this acquisition, GE Aviation expands its engineering and manufacturing capabilities to meet its growing jet engine production rates over the next five years. Morris Technologies (Sharonville, OH) and Rapid Quality Manufacturing (West Chester, OH) have supplied parts to GE Aviation for several years, as well as to GE Power Systems and GE Global Research Center. The Sharonville and West Chester facilities will become part of GE Aviation's global network of manufacturing operations. Both companies focus on the aerospace, energy, oil & gas, and medical industries.
GS Yuasa Li-ion battery cells to power International Space Station
Pratt & Whitney Rocketdyne (PWR) awarded a contract to GS Yuasa Lithium Power Inc. (GYLP) to provide lithium-ion (Li-ion) battery cells to be used on the International Space Station (ISS). PWR will integrate GS Yuasa Li-ion cells into batteries that will replace the nickel-hydrogen (Ni-H2) batteries that currently power the ISS Electrical Power System (EPS) during its eclipse mode. This battery replacement effort is part of an initiative to extend the operation and utilization of the ISS. GS Yuasa will supply its LSE134 Li-ion cell that has completed qualification testing for the ISS program. The LSE134 (134-A·h nameplate capacity) cell is a member of GS Yuasa's Generation III family of Li-ion cells for space and is ideally suited to the electrical, size, and mass requirements of this mission. It approximately triples the available energy storage on both a per mass and a per volume basis relative to the existing Ni-H2 battery and is capable of powering critical ISS systems well beyond the required 10-year service life.
Autodesk, IndyCar sign technology partnership
Autodesk and IndyCar have signed a three-year technology partnership that will give the participants in the IZOD IndyCar Series broad access to the former's cloud-based design and engineering software. The software offerings include Autodesk Product Design Suite, Autodesk Simulation 360, Autodesk Entertainment Creation Suite, and Autodesk PLM 360. This capability will better enable the organization to come up with aerodynamic specifications for components that all race teams can agree on—reducing any advantages or disadvantages among teams and creating a more competitive and exciting racing environment, the companies said in a joint press release issued Nov. 29. IndyCar already employs Autodesk software within its operations for a variety of important functions—for example, AutoCAD is used to create detailed garage layouts before each event, which helps improve the logistics of load-in and load-out at venues. The same product is used in relation to sled crash testing.
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IndyCar's engineering and operations group will use Autodesk Digital Prototyping applications to design and engineer product innovations for chassis designs, parts, and components.
Dana launches Chinese-specific off-highway drivetrain brand
Dana Holding Corp. has developed and launched the Spicer Rui Ma brand for a new class of transmissions and axles made in China to complement the supplier’s flagship Spicer brand. Announced at Bauma China 2012 in Shanghai, the initial Spicer Rui Ma products offered to Chinese OEMs include the Spicer TZL16 RM powershift transmission for ZL50 front-end loaders, the T08 RM transmission for 6- to 10-t (6.6- to 11-ton) forklift trucks, and the T39 RM tridem drive axle for five- and six-axle chassis concrete pump trucks and other heavy-duty vocational applications. The company plans to introduce additional Spicer Rui Ma transmissions and axles for the construction, mining, and material-handling industries in the coming months. Developed and produced at Dana’s manufacturing facility in Wuxi, Jiangsu Province, Spicer Rui Ma transmissions and axles are supported by the supplier’s growing network of engineering, sales support, and aftermarket parts and service teams in China. Dana currently has nine facilities in China and plans to open a 12,000-m2 (129,000-ft2) technical center in Wuxi in early 2013 to provide advanced product and applications engineering.
Saft receives additional funding from BAE Systems for advanced Li-ion ESS
BAE Systems has awarded Saft $1.3 million in new funding to continue development of a lithium-ion (Li-ion) energy storage system (ESS) for the U.S. Army’s Ground Combat Vehicle (GCV) program. The new funding for the GCV project is an addition to the initial 2010 contract. Saft, which is designing and building ultrahigh-power cells for the vehicle’s hybrid-electric drive system, has already completed the demo battery system including hardware and software. Comprised of ultrahigh-power, high-voltage VL 5U cells, the Li-ion ESS supports the GCV’s electric drive system when the vehicle is not running on gasoline, such as during silent watch missions. Saft joins Northrop Grumman, MTU, QinetiQ, and L-3 Communications on the BAE Systems’ GCV team, one of two industry teams working on the technology development phase of the program. The 24-month technology development phase is aimed at completing preliminary design reviews to build prototype systems prior to the engineering and manufacturing phase. Saft believes it will likely be the battery supplier when production begins in 2019, if the BAE Systems/Northrop Grumman team is selected as the Army’s design and manufacturing partner.
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BAE Systems' solution for the U.S. Army’s GCV program—a nine-man Infantry Carrier (plus three crew members) that can protect against threats, move in urban and off-road terrain, and accommodate emerging technologies such as lightweight armor composites and electronics—includes a hybrid-electric drive system.
Motiv ePCS to power heavy electric trucks in Chicago
San Francisco Bay Area-based startup Motiv Power Systems has been chosen to supply its scalable electric Powertrain Control System (ePCS) to the City of Chicago for 20 all-electric garbage trucks, under an exclusive five-year, $13.4 million contract. The City of Chicago operates 600 garbage trucks in total. The ePCS uses off-the-shelf batteries and motors that can be configured to power medium-duty to Class 8 heavy-duty EV trucks, weighing from 15,000 to 52,000 lb (6800 to 23,500 kg). This design approach can cut operating costs by 50% over an eight-year period, according to Motiv. The company, which was founded in 2009, has been validating its ePCS since March 2012 with an all-electric pilot bus. Funded by a grant from the California Energy Commission, the 20-passenger bus contains five battery packs (125 kW·h) providing a range of more than 120 mi (193 km) on a single charge. The Motiv EV refuse trucks planned for Chicago will use the same ePCS system as the pilot bus, but with a larger motor and 10 battery packs, and will also employ an electric motor to drive the hydraulics system. Motiv will work with partner Detroit Chassis to install the ePCS onto a standard refuse chassis; Loadmaster will provide the truck bodies. Weighing 52,000 lb (23,500 kg), the EV refuse trucks will reportedly have a range of more than 60 mi (97 km), with a total energy storage of 200 kW·h. (Go to www.sae.org/mags/sohe/11486 to read about another recent electrified refuse truck project.)
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Weighing 52,000 lb, the Motiv-powered electric refuse trucks in Chicago will have a range of more than 60 mi (97 km), with a total energy storage of 200 kW·h.
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