Simulation helps uncover EV myths

Pepi Maximovich writes that the market leader of the e-mobility revolution is defined by the speed and effectiveness of innovation.

The adoption of electric vehicles (EVs) is on the rise. In 2021 alone, pure electric vehicles on UK roads will increase by 76% compared to 2020, and this number is expected to increase further in 2022. In December 2021, more than 21% of new cars sold in Europe and the United Kingdom that month were powered solely by electricity.

Even in motorsport, known for its complex performance requirements, you can drive the circuit with powerful electric motors such as the Porsche Formula E car Porsche 99x Electric. Many automakers are testing Formula E race car ideas and models before tackling consumer EVs. Simulation allows engineers to test batteries, power electronics, motors, and controls in a fully virtualized environment.

EVs can bring many benefits to the environment, but the main challenges lie in production, high-volume supply chain bottlenecks, costs, and common misconceptions among consumers. For example, potential UK buyers are concerned that EVs do not have a battery range to travel long distances or are not charged fast enough. The steady reduction in battery prices accelerated by simulation is impacting the total and operating costs of many top EVs, especially in the midst of the economic downturn.

Simulations allow engineers to understand how a vehicle reacts and behaves in real-world scenarios, consuming large amounts of carbon and reducing the need for costly physical testing.

These extraordinary design challenges posed by electrification require similarly extraordinary solutions, with the UK’s bold goal of phased out new gasoline and diesel sales by 2030. The transition to EV, driven by innovative technology strategies, is these current and additional ambitious Net Zero targets. To meet these climatic goals, manufacturers are obliged to continually improve all components of the vehicle, from in-vehicle energy consumption and driving experience to batteries. However, as consumers are constantly considering the availability of charging infrastructure, charging speeds, high purchase prices, etc., there remains a trust gap between manufacturers and consumers when it comes to EVs.

Engineering simulation is one way to address the design requirements that define the success of EV market development, and the market leaders of the EV revolution need to realize the speed and effectiveness of their ability to produce EVs for the mass market. I have. How can I use simulation to break the EV misunderstanding barrier?

Break the bank? Weigh the cost of EV

The initial purchase cost of an EV is higher than that of an internal combustion engine vehicle, but improvements and innovations can reduce the price. The answer lies in the use of powerful and comprehensive engineering simulation software that enables engineers to investigate and predict how batteries, components, and the entire system will work (or fail). Importantly, simulations allow engineers to understand how the vehicle reacts and behaves in real-world scenarios, consuming large amounts of carbon and reducing the need for costly physical testing. I can do it. By replacing physical tests with virtual tests on computers, automotive companies are significantly accelerating the pace of innovation, improving performance and processes, reducing the risk of product failures, and reducing costs. ..

Simulation allows engineers and designers to view the product (EV in this case) in X-ray vision. By understanding how a car reacts in a physical scenario without the need for a physical prototype, much more situations such as compliance and traffic safety environments that were not previously available to production teams. Can be visualized. Automakers can accelerate their innovation strategies to bring vehicles to the highly competitive and profitable electrification market faster, with higher quality and at lower cost. In addition, affordability, especially in new technologies, is the basis of large-scale adoption.

The extraordinary design challenges posed by electrification require extraordinary solutions as well.

Can EVs provide battery range and power to meet travel needs?

One of the biggest consumer concerns about EVs is the perception that EVs do not have enough driving ranges to give drivers confidence in their travels. Range anxiety.. However, many players need to change their minds, suggesting that EVs are a lot like mobile phones, smartwatches, or headphones that owners charge every night. Of course, EVs offer the great advantage of taking the time to find a local gas station, waiting in line to refuel, and eliminating the need to pay for soaring fuel prices.

It is important to encourage engineers and automakers to constantly provide new vehicles with seamless experiences and journeys, and EV producers should provide traditional fuel stops and competitive owner charging times. Is working on. Accelerating product design and getting to market early with innovative products offers competitive and branding benefits. Not only this, simulation can significantly improve reliability, reduce warranty costs, and damage your car brand.

EV Battery Overload: What’s Next?

With millions of electric vehicles on the road, there are major challenges to what to do with EV batteries at the end of their life and the feasibility of a circular economy when it comes to batteries. EVs do not emit CO2 into the atmosphere through tailpipe emissions, but there is ongoing debate about how to manage the environmental footprint of batteries, including how to dispose of them responsibly. Currently, the world lacks the technology to recycle EV batteries on a large scale. 5% of lithium-ion batteries It is recycled in total.

Many existing processes need to be calculated and redesigned to meet the ambitious Net Zero goal.

EV batteries are a complex and highly engineering feat, consisting of numerous cells, modules, and packs. Engineers should make the battery as compact as possible to minimize space while improving overall performance in terms of thermal management, safety standards compliance, structural reliability and full integration. In order to try, it is required to include numerous design innovations in the battery occupy. For this reason, it can be very difficult to make it feasible to recycle and add to the Circular Economy Loop. why? EV parts are made up of well-manufactured parts, making it difficult and time-consuming to disassemble a large number of complex parts. Automation and robots can assist in this with the help of simulations to test the process. Another solution is to make the battery last as long as possible and make it environmentally friendly. To ensure that the circular economy is achieved at some point, it is important to design it to extend its lifespan.

The transformation of EV is very compelling. The bold and ambitious Net Zero mission statement by top automotive brands is underpinned by huge investments. The global economy is migrating to clean renewable energy sources with portable energy storage solutions across all major technology sectors. However, many processes that currently exist need to be redesigned to meet the ambitious Net Zero goal. There is also a need to increase consumer demand for products that are better for the planet and people.

Concerns about EVs are widespread throughout the UK and Europe. From consumer hesitation at a higher cost price on the first purchase of a vehicle, to driving range concerns, to the feasibility of recycling EV batteries. Many of these key challenges to improving EVs are costly, time consuming and difficult to achieve with physical prototyping, using engineering simulation software, and a huge number of advanced real vehicles. You can overcome it by testing the scenario. Automakers and suppliers have a great responsibility to realize the Net Zero initiative. We also have the opportunity to work together and work together to provide better, cleaner, more environmentally friendly and more sustainable vehicles for the planet and people.

About the author: Pepi Maksimovic, Ansys Simulation helps uncover EV myths

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