• • • ELECTRIC VEHICLES • • • Design & development for future mobility
As the world gears up for the switch to electric vehicles (EVs), Contechs, an award- winning design and engineering consultancy, has identified the challenges facing the industry and the solutions required to facilitate this global shift
perating as a strategic partner to the automotive industry, Contechs provides innovative design and engineering services to global OEMs, from concept to production. The global automotive consultancy is instrumental in developing EV technology and architecture for its prestigious OEM clients, and continually evaluates the EV market to align its agile electrical strategy. Improving EV range is integral to Contechs’ EV engineering methodologies. Customers are no longer selecting their next vehicle based on looks and brand loyalty alone; vehicle range is also an ever-increasing requirement. To tackle this issue, Contechs is currently exploring innovative engineering solutions that allow EVs to catch up to traditional internal combustion engine (ICE) vehicles. This research includes lightweighting, alternative body materials, integrated power electronics, and aerodynamics. Through effective collaboration between its centres of competence, Contechs incorporates advancements in these areas throughout the entire product development process. Another issue facing the industry is the high price tag of EVs. Contechs’ analysis of the market sector found that 56% of UK motorists considering an EV as their next car have concerns over its high purchase cost. One way the industry is combating this issue is through joint ventures, which facilitate increased manufacturing volumes and therefore reduced consumer outlay. However, joint ventures bring their own challenges, driving the need to develop more computer-aided engineering (CAE) augmented tool sets for simulation and validation, without the need for expensive prototypes. Contechs has invested heavily in these tools along with its cloud-based
O
systems, allowing it to remain at the forefront of EV trends and be best positioned to service its global customer base.
During the design and engineering of its EV programmes, Contechs facilitates virtual series reviews, linked real-time with its clients and global teams. Its advanced CAE capabilities have achieved some remarkable results in delivering more cost effective EVs for the future. The EV vehicle market is ever increasing; however, the challenge is not only about the number of vehicles to market but also the supporting infrastructure. One such solution to this problem may be ‘battery swapping’ or ‘battery switching’. This technology allows battery electric
vehicles to quickly exchange a discharged battery pack for a fully charged new one, as an alternative to recharging the vehicle via a charging station. Chinese carmaker NIO has invested considerably in this emerging technology and is now beginning operations in Europe, having conducted successful trials in China. Costing €0.20/kWh, plus a €10 flat fee for using its European swap stations, the maximum cost for a 100kWh battery swap stands at €30 – or roughly half of what you would expect to pay at a conventional rapid charger. Contechs has conducted extensive benchmarking in this field of research, which has manifested in the development of modular electrical architectures with intelligent skateboard configurations and software defined vehicle connectivity that has enabled the use of battery swapping. Ian Trueman, electrical & electrification director at Contechs, says: “As EV development continues to evolve, we have recognised the shift in the market to reduce weight, increase range, and drive commonality across the industry. “By adjusting our electrical strategy, we are now able to deliver lightweight alternative body structures and materials, as well as integrated electrical solutions from a detailed skateboard solution to a complete vehicle.”
Over the next five years, Contechs plans to invest heavily in research and development of battery cell technology and CAE tools, as well as launching an industry-first Systems Engineering Training Academy. This academy aims to train graduate and traditional ICE engineers in high and low voltage engineering.
Starting in 2024, this programme will address the skills shortage across the industry and is being recognised as a fundamental support structure for the 2035 UK ‘Net Zero Pledge’ deadline.
26 ELECTRICAL ENGINEERING • FEBRUARY 2024
electricalengineeringmagazine.co.uk
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