AUTOMOTIVE
STAYING AHEAD IN EV DESIGN
According to Next Green Car, 2021 saw the largest ever annual increase in the number of electric vehicle registrations. Over 305,000 were registered, a 74 per cent increase compared with 2020. Here Simon Ward, technical manager at TFC, shares three ways EV manufacturers can stay ahead of the demand curve.
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n 2021, the Government brought forward its ban on new petrol and diesel vehicles from 2040 to 2030. This target has accelerated the EV market boom, creating pressure on design teams to deliver innovation, and impetus on production teams to
maximise capacity. So, what can design teams do to stay ahead of consumer demand?
COPING WITH INCREASED ROTATIONAL REQUIREMENTS Drive systems for EVs typically have much higher rotational capacity requirements than internal combustion engine vehicles (ICEs) - 15,000 revolutions per minute (rpm) or more. These applications where high rpm is integral to a product’s function can pose design challenges, because traditional retaining rings fitted on rotating shafts are limited by centrifugal forces and can yield during installation due to the component’s heavy cross-section. Higher rpm risks the centrifugal
forces becoming great enough to expand and lift the retaining ring from the groove, causing assembly failure at high speed. Options to reduce this risk include adding wire ties through the holes of the circlip, or using an additional component to captivate the outside diameter and thus prevent ring expansion. However, these approaches can increase assembly time, weight and add significant additional costs to the finished product. EV manufacturers can face this challenge head on by specifying technical components designed specifically for high rpm. Smalley Revolox Self-Locking Retaining Rings, for example, have a ‘dimple and slot’ design that means that after installation, the dimple is trapped in the slot and the ring locks into place. As the ring rotates it expands, engaging the dimple and slot mechanism and preventing any further expansion. Compared with non-locking alternatives, this offers a much higher rpm capacity.
Autumn 2022 UKManufacturing
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