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Conductive Brush Ring overcomes current leakage in EV powertrains

SKF's new Conductive Brush Ring paves the way to greater reliability and longer life in high-performance electric vehicle powertrain systems. Using pure carbon fiber bristles, it provides a reliable electrical connection between an EV eAxle rotor shaft and its housing. When used in combination with SKF Hybrid ceramic ball bearings, it helps to alleviate parasitic current effects that can lead to premature failure in bearings and other components. Available in different configurations for wet (oil-lubricated) motor designs -- and soon for dry (sealed) applications.
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Intro to reed switches, magnets, magnetic fields

This brief introductory video on the DigiKey site offers tips for engineers designing with reed switches. Dr. Stephen Day, Ph.D. from Coto Technology gives a solid overview on reed switches -- complete with real-world application examples -- and a detailed explanation of how they react to magnetic fields.
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Bi-color LEDs to light up your designs

Created with engineers and OEMs in mind, SpectraBright Series SMD RGB and Bi-Color LEDs from Visual Communi-cations Company (VCC) deliver efficiency, design flexibility, and control for devices in a range of industries, including mil-aero, automated guided vehicles, EV charging stations, industrial, telecom, IoT/smart home, and medical. These 50,000-hr bi-color and RGB options save money and space on the HMI, communicating two or three operating modes in a single component.
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All about slip rings: How they work and their uses

Rotary Systems has put together a really nice basic primer on slip rings -- electrical collectors that carry a current from a stationary wire into a rotating device. Common uses are for power, proximity switches, strain gauges, video, and Ethernet signal transmission. This introduction also covers how to specify, assembly types, and interface requirements. Rotary Systems also manufactures rotary unions for fluid applications.
Read the overview.

Seifert thermoelectric coolers from AutomationDirect

Automation-Direct has added new high-quality and efficient stainless steel Seifert 340 BTU/H thermoelectric coolers with 120-V and 230-V power options. Thermoelectric coolers from Seifert use the Peltier Effect to create a temperature difference between the internal and ambient heat sinks, making internal air cooler while dissipating heat into the external environment. Fans assist the convective heat transfer from the heat sinks, which are optimized for maximum flow.
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EMI shielding honeycomb air vent panel design

Learn from the engineering experts at Parker how honeycomb air vent panels are used to help cool electronics with airflow while maintaining electromagnetic interference (EMI) shielding. Topics include: design features, cell size and thickness, platings and coatings, and a stacked design called OMNI CELL construction. These vents can be incorporated into enclosures where EMI radiation and susceptibility is a concern or where heat dissipation is necessary. Lots of good info.
Read the Parker blog.

What is 3D-MID? Molded parts with integrated electronics from HARTING

3D-MID (three-dimensional mechatronic integrated devices) technology combines electronic and mechanical functionalities into a single, 3D component. It replaces the traditional printed circuit board and opens up many new opportunities. It takes injection-molded parts and uses laser-direct structuring to etch areas of conductor structures, which are filled with a copper plating process to create very precise electronic circuits. HARTING, the technology's developer, says it's "Like a PCB, but 3D." Tons of possibilities.
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Loss-free conversion of 3D/CAD data

CT CoreTech-nologie has further developed its state-of-the-art CAD converter 3D_Evolution and is now introducing native interfaces for reading Solidedge and writing Nx and Solidworks files. It supports a wide range of formats such as Catia, Nx, Creo, Solidworks, Solidedge, Inventor, Step, and Jt, facilitating smooth interoperability between different systems and collaboration for engineers and designers in development environments with different CAD systems.
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Top 5 reasons for solder joint failure

Solder joint reliability is often a pain point in the design of an electronic system. According to Tyler Ferris at ANSYS, a wide variety of factors affect joint reliability, and any one of them can drastically reduce joint lifetime. Properly identifying and mitigating potential causes during the design and manufacturing process can prevent costly and difficult-to-solve problems later in a product lifecycle.
Read this informative ANSYS blog.

Advanced overtemp detection for EV battery packs

Littelfuse has introduced TTape, a ground-breaking over-temperature detection platform designed to transform the management of Li-ion battery systems. TTape helps vehicle systems monitor and manage premature cell aging effectively while reducing the risks associated with thermal runaway incidents. This solution is ideally suited for a wide range of applications, including automotive EV/HEVs, commercial vehicles, and energy storage systems.
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Benchtop ionizer for hands-free static elimination

EXAIR's Varistat Benchtop Ionizer is the latest solution for neutralizing static on charged surfaces in industrial settings. Using ionizing technology, the Varistat provides a hands-free solution that requires no compressed air. Easily mounted on benchtops or machines, it is manually adjustable and perfect for processes needing comprehensive coverage such as part assembly, web cleaning, printing, and more.
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LED light bars from AutomationDirect

Automation-Direct adds CCEA TRACK-ALPHA-PRO series LED light bars to expand their offering of industrial LED fixtures. Their rugged industrial-grade anodized aluminum construction makes TRACKALPHA-PRO ideal for use with medium to large-size industrial machine tools and for use in wet environments. These 120 VAC-rated, high-power LED lights provide intense, uniform lighting, with up to a 4,600-lumen output (100 lumens per watt). They come with a standard bracket mount that allows for angle adjustments. Optional TACLIP mounts (sold separately) provide for extra sturdy, vibration-resistant installations.
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World's first metalens fisheye camera

2Pi Optics has begun commercial-ization of the first fisheye camera based on the company's proprietary metalens technology -- a breakthrough for electronics design engineers and product managers striving to miniaturize the tiny digital cameras used in advanced driver-assistance systems (ADAS), AR/VR, UAVs, robotics, and other industrial applications. This camera can operate at different wavelengths -- from visible, to near IR, to longer IR -- and is claimed to "outperform conventional refractive, wide-FOV optics in all areas: size, weight, performance, and cost."
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Orbex offers two fiber optic rotary joint solutions

Orbex Group announces its 700 Series of fiber optic rotary joint (FORJ) assemblies, supporting either single or multi-mode operation ideal for high-speed digital transmission over long distances. Wavelengths available are 1,310 or 1,550 nm. Applications include marine cable reels, wind turbines, robotics, and high-def video transmission. Both options feature an outer diameter of 7 mm for installation in tight spaces. Construction includes a stainless steel housing.
Learn more.

Mini tunnel magneto-resistance effect sensors

Littelfuse has released its highly anticipated 54100 and 54140 mini Tunnel Magneto-Resistance (TMR) effect sensors, offering unmatched sensitivity and power efficiency. The key differentiator is their remarkable sensitivity and 100x improvement in power efficiency compared to Hall Effect sensors. They are well suited for applications in position and limit sensing, RPM measurement, brushless DC motor commutation, and more in various markets including appliances, home and building automation, and the industrial sectors.
Learn more.

Scientists discover how oxygen loss saps a lithium-ion battery's voltage

When lithium ions flow in and out of a battery electrode during charging and discharging, a tiny bit of oxygen seeps out and the battery's voltage -- a measure of how much energy it delivers -- fades an equally tiny bit. The losses mount over time, and can eventually sap the battery's energy storage capacity by 10-15%.

Now, researchers have measured this super-slow process with unprecedented detail, showing how the holes, or vacancies, left by escaping oxygen atoms change the electrode's structure and chemistry and gradually reduce how much energy it can store.

The results contradict some of the assumptions scientists had made about this process and could suggest new ways of engineering electrodes to prevent it.

The research team from the Department of Energy's SLAC National Accelerator Laboratory and Stanford University described their work in Nature Energy, June 14, 2021.

"We were able to measure a very tiny degree of oxygen trickling out, ever so slowly, over hundreds of cycles," said Peter Csernica, a Stanford PhD student who worked on the experiments with Associate Professor Will Chueh. "The fact that it's so slow is also what made it hard to detect."

A two-way rocking chair
Lithium-ion batteries work like a rocking chair, moving lithium ions back and forth between two electrodes that temporarily store charge. Ideally, those ions are the only things moving in and out of the billions of nanoparticles that make up each electrode. But researchers have known for some time that oxygen atoms leak out of the particles as lithium moves back and forth. The details have been hard to pin down because the signals from these leaks are too small to measure directly.

"The total amount of oxygen leakage, over 500 cycles of battery charging and discharging, is 6%," Csernica said. "That's not such a small number, but if you try to measure the amount of oxygen that comes out during each cycle, it's about one one-hundredth of a percent."

In this study, researchers measured the leakage indirectly instead, by looking at how oxygen loss modifies the chemistry and structure of the particles. They tracked the process at several length scales -- from the tiniest nanoparticles to clumps of nanoparticles to the full thickness of an electrode.

Because it's so difficult for oxygen atoms to move around in solid materials at the temperatures where batteries operate, the conventional wisdom has been that the oxygen leaks come only from the surfaces of nanoparticles, Chueh said, although this has been up for debate.

In this illustration, the pairs of red spheres are escaping oxygen atoms and purple spheres are metal ions. This new understanding could lead to new ways to minimize the problem and improve battery performance. [Credit: Greg Stewart/SLAC National Accelerator Laboratory]

 

 

 

 

To get a closer look at what's happening, the research team cycled batteries for different amounts of time, took them apart, and sliced the electrode nanoparticles for detailed examination at Lawrence Berkeley National Laboratory's Advanced Light Source. There, a specialized X-ray microscope scanned across the samples, making high-res images and probing the chemical makeup of each tiny spot. This information was combined with a computational technique called ptychography to reveal nanoscale details, measured in billionths of a meter.

Meanwhile, at SLAC's Stanford Synchrotron Light Source, the team shot X-rays through entire electrodes to confirm that what they were seeing at the nanoscale level was also true at a much larger scale.

A burst, then a trickle
Comparing the experimental results with computer models of how oxygen loss might occur, the team concluded that an initial burst of oxygen escapes from the surfaces of particles, followed by a very slow trickle from the interior. Where nanoparticles glommed together to form larger clumps, those near the center of the clump lost less oxygen than those near the surface.

Another important question, Chueh said, is how the loss of oxygen atoms affects the material they left behind. "That's actually a big mystery," he said. "Imagine the atoms in the nanoparticles are like close-packed spheres. If you keep taking oxygen atoms out, the whole thing could crash down and densify, because the structure likes to stay closely packed."

Since this aspect of the electrode's structure could not be directly imaged, the scientists again compared other types of experimental observations against computer models of various oxygen-loss scenarios. The results indicated that the vacancies do persist -- the material does not crash down and densify -- and suggest how they contribute to the battery's gradual decline.

"When oxygen leaves, surrounding manganese, nickel, and cobalt atoms migrate. All the atoms are dancing out of their ideal positions," Chueh said. "This rearrangement of metal ions, along with chemical changes caused by the missing oxygen, degrades the voltage and efficiency of the battery over time. People have known aspects of this phenomenon for a long time, but the mechanism was unclear."

Now, he said, "we have this scientific, bottom-up understanding" of this important source of battery degradation, which could lead to new ways of mitigating oxygen loss and its damaging effects.

Source: DOE/SLAC National Accelerator Laboratory

Published June 2021

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