New Products

Coating Thickness Measurement System

Micro-Epsilon (Raliegh, NC) has introduced optical sensors for performing thickness measurements of all coatings. Micro-Epsilon’s optoNCDT 1900 sensors operate at high resolution and can be used in both wet and dry coating processes. Due to the small light spot diameters, even the smallest of details can be reliably detected. In addition, measurements are performed with high dynamism. The thicknessGAUGE O.EC turnkey system detects the thickness of electrode coatings. It uses the innovative combiSENSOR that combines an eddy current sensor measuring onto the guide roller, and a capacitive sensor to measure the distance from the coating surface. The exact thickness value of the electrode coating is obtained from the signal difference. The sensors are designed for reliable and precise measurements in high, fluctuating ambient temperatures.

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Lithium-Ion Battery Stations

DENIOS (Louisville, KY) has introduced lithium-ion stations designed specifically for storing lithium-ion batteries, and are ideal for storing new, questionable, damaged, defective, or End-of-Life lithium-ion batteries typically found in small handheld devices. Available in two standard sizes, they allow the storage storing and transportation of batteries from 1 KG to 10 KG up to 100 W, which are typically used in power tools, e-bikes, medical devices, laptops, tablets, mobile devices, forklifts, cars, and more. With two hours of fire resistance, and integrated forklift pockets for easy relocation, these purpose-built containers protect against fire hazards due to thermal runaway, deep discharge, mechanical deformation, or chemical reaction. Each unit includes thermo-dissipative media (class D fire), and visual identification on all sides to alert emergency personnel of contents and hazards.

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Gearboxes for Electric Motors

As part of its new, extensive eLION platform for the electrification of mobile working machines, Bosch Rexroth (Bethlehem, PA) has developed spur gearboxes which vehicle manufacturers can use to unlock the full potential of new electric motors. The one- and two-speed gearboxes are installed in the central section of the vehicle and pool the energy to drive up to two axles with just one motor. The clever integration of essential components is evidence of the wealth of practical know-how that was drawn on throughout the development process. The one-speed spur gearbox (eGFZ 9100) and the two-speed shift gearbox (eGFZ 9200) are installed in the central section of the vehicle, and therefore, open up a range of new options compared to previous approaches with individual wheel drives. Both gearboxes enable high power densities to be achieved while simultaneously ensuring noise optimization for high-speed electric motors.

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Battery Test Systems

Keysight’s (Santa Rosa, CA) Battery Test Solution supports the research and development process of any battery cell, module and pack with innovative test systems, control and test. The Scienlab SL1000A Battery Test System Pack Level is an electric system to provide sink and source for high voltage battery packs for automotive and industrial applications. This solution ensures optimized test lab operation by managing resources, hardware and information providing comprehensive functions for planning and execution of test procedures. Its key features include synchronized control of all components in the test environment, e.g., climate chamber, conditioning of the device under test (DUT), and Battery Management System (BMS); recorded measured values to use as a variable during the remainder of the test sequence; direct evaluation of data using practical analysis tools: post-processing is not necessary.

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Leak Testing of Sealed Batteries

Marposs (Auburn Hills, MI) has announced its new automatic machine for leak testing of sealed batteries in high production environments. This patent pending system is based on electrolyte tracing, which makes it possible to perform the leak test after it has been filled with the electrolytes and completely sealed. Perfect sealing is necessary to prevent the loss of electrolytes, often composed of flammable solvents which can produce toxic substances if they come in contact with humidity in the air. The ability of the Marposs system to test after filling and sealing provides higher quality verification of batteries being used in electric vehicle production. Cells can be tested in different stages of the production process: immediately after electrolyte filling and sealing, after formation, or after degassing and subsequent final sealing, and up to the check during the end-of-line testing. The system is available in three versions: cylindrical and button cells, prismatic cells, and pouch cells.

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Automotive Power Modules

Nexperia (Nijmegen, The Netherlands) has partnered with KYOCERA AVX Components Gmbh (Salzburg, Germany), for covering gallium nitride (GaN) automotive power modules, with the aim of jointly developing GaN applications for electric vehicles. As passenger vehicles become increasingly electrified, the demand for power semiconductors to provide efficient power conversion at increasingly higher power densities also grows. High voltage Power GaN FETs, when combined with innovative packaging technologies, can address the requirements for better efficiency, higher power density and reduced system cost. Nexperia manufactures GaN devices in its own facilities using mature mass production techniques which have been proven to meet the highest reliability requirements for devices to achieve AEC-Q101 certification and automatic parking functions with 3D visualization effects.

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Thermally Conductive Battery Adhesive

DELO (Sudbury, MA) now offers a structural adhesive for batteries used in hybrid vehicles. Designed for high-volume series production, DELO-DUOPOX TC8686 is thermally conductive and flame-retardant. This new adhesive is suitable for low-voltage batteries found in mild hybrid and conventional hybrid vehicles, as well as in e-bikes and e-scooters. The adhesive allows battery cells to be bonded into a battery’s housing while dissipating the heat generated during operation. Instead of mechanically connecting the battery cells and then using gap fillers for heat dissipation, DELO-DUOPOX TC8686 combines connection of the thermal management system and structural bonding into one step, simplifying production. It offers a simple mixing ratio of 2:1 and has a processing time of approximately 30 minutes after mixing. This is long enough for prototypes and small series and fast enough for fully automated systems. After four hours, the adhesive reaches its initial strength. Ninety percent of its final strength can be achieved after 24 hours.

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Modular Battery Pack

The XPAND Modular Pack (XMP) from XALT (Midland, Ml) is the core building block of XALT Energy’s state of the art Energy Storage Systems (ESS) based on its lithium-ion cell designs. XMP is designed for use in multiple applications including hybrid and electric commercial truck, bus and heavy-duty transportation; hybrid and electric marine power and propulsion, rail and mining applications. XMP core accommodates cells in XALT’s 225-mm family without the need for retooling, anticipating a wide variety of application voltage, power, and energy. As cell technologies advance or packs become available for re-purposing, the XMP core can be replaced while all external interfaces remain the same. XMP’s advanced active liquid cooling system maintains ideal cell temperatures throughout the pack and responds quickly to increases in power demand and changes in ambient (environmental) temperatures.

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Emergency Battery Power Supply

True Blue Power’s (Wichita, KS) TS60 is a direct replacement for Honeywell Grimes power supplies and battery assemblies. It features advanced NanoPhosphate® lithium-ion cell chemistry and saves operators time and money with easier installation and significantly reduced maintenance, only requiring two-year capacity checks, and a life expectancy of eight years. The TS60 utilizes aircraft power to recharge and maintain full capacity. It provides more power than needed to meet the required 20 minutes of emergency lighting run time. The advanced, four-cell configuration offers up to 30 minutes of power and then recharges to full capacity within minutes. This new Part 25 AML STC adds to the growing number aircraft flying with the TS60. The True Blue Power® Emergency Battery Power Supply was STC approved on the De Havilland DHC-8 Series, including the Q400, in 2018.

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