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Electrification

Everything that carries current and moves

A car, a drone, a lift aircraft, a boat and a truck look like five different problems. In the record they are one: how much energy you can carry, how fast you can put it back, and what the heat does while you do.

Tell us what you are building

Why the shapes matter less than they look

A pack is a pack whether it sits under a floor, in a wing or in a hull. The cell chemistry, the way heat leaves it, the current the interface can take and the standard that governs that interface are the same four questions every time. What changes is which one bites first.

In a car it is usually charge time. In a drone it is mass. In an aircraft it is the reserve you must still have when you land. In a boat it is what the water does to the cooling. Knowing which one governs your design is most of the first month, and it is readable long before it is buildable.

The order in which they bite is also the order in which they get expensive. A cell chosen badly is a purchase order. A thermal path designed badly is a redesign. A charging interface aimed at the wrong standard is a product that works and cannot be sold.

An electric motor seen end on, with the inverter beside it A motor drawn as concentric circles seen from the end. Twelve stator poles stand around the rim and eight rotor magnets sit inside them in violet. A glowing line runs from the motor to a power electronics box on the right with three cooling channels. A measurement line spans the motor diameter. Along the bottom stand the words stator, rotor and inverter. STATOR . ROTOR . INVERTER
Ett elfordon
Charging posts in an underground garage. The cable is where the heat turns up first, and it is the part nobody budgets for.

01. The car

The motor is solved. The heat is not

Permanent magnet machines and the inverters that drive them are mature, well documented and available from more than one supplier. That part of the record is thick and mostly settled.

What still ends projects is what happens between the cell and the air: the path heat takes out of the pack, and whether the charging interface you designed against is the one the market will have when you ship. Both are in the record, filed by people who found out the expensive way.

A four rotor drone seen from above with its camera line below A drone drawn from above. A body in the middle carries four arms out to four rotors, each shown as a thin violet ellipse that turns. Under the body a camera looks down and a glowing line falls to a point on a help line. A measurement line spans the rotor span. Along the bottom stand the words lift, endurance and payload. LIFT . ENDURANCE . PAYLOAD
En drönare i luften med last
A quadcopter in the air. Every gram it carries is paid for again in the frame, the motor, the battery and the endurance.

02. The drone

Every gram is paid for four times

A gram added to a rotorcraft is paid in structure, in the motor that has to lift it, in the cell that has to feed that motor, and in the structure that has to carry the bigger cell. That loop is why drone projects converge slowly and then all at once.

We read the mass loop before the first frame is cut, and we read what the airspace rules will require of the payload you are planning. A camera that needs a certification you did not budget for is cheaper to find in a document than in a flight test.

The loop closes faster than most teams expect. On a small airframe, a hundred grams of added payload can cost three hundred grams of take off mass by the time the structure has caught up with it.

A lift and cruise aircraft with six rotors seen from the front An aircraft body with a wing to each side, drawn in thin outline. Six lift rotors stand above the wing as violet ellipses on short masts. One glowing arrow points up for lift and one points right for cruise. A measurement line spans the wing. Along the bottom stand the words lift, cruise and transition. LIFT . CRUISE . TRANSITION
En helikopter i luften
A helicopter with the engine off. Holding a machine still in the air costs power every second it lasts, whatever the energy comes from.

03. Lift aircraft and helicopters

Hover is expensive and cruise is cheap

A rotorcraft spends most of its energy standing still in the air. A wing spends most of its energy going somewhere. Every lift and cruise design is an argument about how long you have to do the first before you are allowed to do the second.

The transition between them is where the patents are dense and where the certification path is least settled. We map both before a configuration is chosen, because changing configuration later means starting the aerodynamics again.

An electric aircraft seen from the front with battery bays in the wings An aircraft drawn from the front in thin outline. A propeller turns above the nose and a glowing line runs up into it. Each wing carries eight battery bays marked in violet. A measurement line spans the wingspan. Along the bottom stand the words energy, mass and reserve. ENERGY . MASS . RESERVE
Ett eldrivet flygplan
The Helios prototype on a dry lakebed. A wing that size exists because the energy budget was settled before the airframe was drawn.

04. Electric aircraft

The reserve is the design

A battery aircraft must land with energy it was never allowed to use. That reserve is written into the rules, it does not shrink because the flight went well, and it is the single number that decides whether a route closes or opens.

An electric boat with the pod drive lit under the waterline A boat drawn in thin outline from the side, sitting on a moving blue water line. Under the hull a battery pack with six cells is marked in violet, and a glowing line runs from it back to a pod drive with a propeller. A measurement line spans the hull. Along the bottom stand the words displacement, range and wake. DISPLACEMENT . RANGE . WAKE
En eldriven båt
A solar electric passenger boat at La Rochelle. The water cools the hull for nothing and takes the salt as payment.

05. Electric boats

The water is a gift and a problem

A hull sits in the best coolant a vehicle could ask for, and in the most corrosive environment a pack could be put in. The first fact makes thermal design easy. The second decides how long the boat lasts.

Displacement hulls reward efficiency in a way road vehicles do not, because the power needed rises sharply with speed. A boat designed around the speed it actually travels at is a different boat from one designed around its top speed.

An electric truck charging, with the power curve drawn above A truck with cab and trailer drawn in thin outline from the side. A battery pack with eight cells sits between the axles in violet. A glowing cable runs from a charging post on the right to the truck, and a blue curve above shows power falling as the pack fills. A measurement line spans the vehicle. Along the bottom stand the words megawatt, duty cycle and depot. POWER MEGAWATT . DUTY CYCLE . DEPOT
Eldriven tung transport
A trolleybus under overhead line. One answer is to carry the energy along, the other is to feed it the whole way, and both are still running.

06. Trucks and trains

Two answers to the same question

A train solved the energy problem by never carrying it: the wire is above and the pantograph reaches up. A truck carries everything it needs and then has to put it back faster than anyone finds comfortable.

Both roads are open for heavy transport and both have a record worth reading. Which one fits depends on the duty cycle, and the duty cycle is measurable long before a vehicle exists.

The drawings

What we draw while we read

Every engagement leaves a set of drawings like these. It is how a claim, a standard or a measurement becomes something a team can argue about in a room.

  • An electric motor seen end on, with the inverter beside it A motor drawn as concentric circles seen from the end. Twelve stator poles stand around the rim and eight rotor magnets sit inside them in violet. A glowing line runs from the motor to a power electronics box on the right with three cooling channels. A measurement line spans the motor diameter. Along the bottom stand the words stator, rotor and inverter. STATOR . ROTOR . INVERTER
  • One cell becoming a module and then a pack Three drawings side by side joined by arrows. On the left a single cell with two terminals. In the middle a module holding five cells in violet. On the right a pack holding twelve modules in a grid, with a glowing line rising from it. The words cell, module and pack stand under each. Along the bottom stand the words chemistry, thermal path and serviceability. CELL MODULE PACK CHEMISTRY . THERMAL PATH . SERVICEABILITY
  • A charging curve where power falls as the cell fills A chart with two axes. A blue line holds high and then falls away in steps as it moves right, and a violet line rises to meet it. A charging connector stands to the left of the chart with a glowing lead into it. Along the bottom stand the words taper, temperature and time at plug. POWER STATE OF CHARGE TAPER . TEMPERATURE . TIME AT PLUG
  • A train collecting current from an overhead line A carriage drawn in thin outline on a track. On its roof a pantograph reaches up in a V to a blue overhead wire, and a glowing line runs between them. Seven windows are marked along the side and four wheels below. Along the bottom stand the words catenary, pantograph and regeneration. CATENARY . PANTOGRAPH . REGENERATION
  • A helicopter drawn from the side with the rotor head lit A helicopter in thin outline seen from the side. Five blades run out from a rotor head at the top, drawn as violet strips. The body curves back into a tail boom and ends in a tail rotor shown as a circle with a cross. A glowing line runs up into the rotor head. A measurement line spans the rotor diameter. Along the bottom stand the words rotor head, tail authority and torque. ROTOR HEAD . TAIL AUTHORITY . TORQUE
  • A printer building an object layer by layer, with the layers enlarged beside it A gantry frame with a nozzle in the middle. A glowing line falls from the nozzle onto a stack of thin layers that grows narrower towards the top, the highest ones marked in violet. To the right a circle enlarges six layers so the bonding between them can be seen. A measurement line spans the base. Along the bottom stand the words layer, adhesion and tolerance. LAYER . ADHESION . TOLERANCE
  • Five composite plies stacked, each with its own fibre direction Five thin sheets drawn in perspective and stacked on top of each other. In each sheet short violet strokes show the fibre direction, and the angle is written to the right of each layer. A glowing line falls onto the top sheet. A measurement line spans the stack. Along the bottom stand the words stiffness, mass and lay up. 0 DEG 45 DEG 90 DEG -45 DEG 0 DEG STIFFNESS . MASS . LAY UP
  • The life of a battery drawn as a ring with five stops Five circles stand around a faint ring, marked build, use, measure, reuse and recover. A glowing arc runs from the first towards the second. Below the ring a branch leads down to a smaller pack with three cells marked in violet. Along the bottom stand the words second life and material recovery. BUILD USE MEASURE REUSE RECOVER SECOND LIFE . MATERIAL RECOVERY
  • Wind and solar feeding a store at the edge of the grid A wind turbine stands on the left with three violet blades, a solar array lies in the middle drawn in perspective, and a store stands on the right holding four cells. Glowing lines run from both sources into the store. The words wind, solar and storage stand under each. Along the bottom stand the words intermittency, firming and grid edge. WIND SOLAR STORAGE INTERMITTENCY . FIRMING . GRID EDGE
  • Two emission lines crossing at the point where the electric vehicle pays back A chart with distance along the bottom and emissions up the side. A cool line starts at zero and rises steeply. A violet line starts higher, because building the battery costs something, and rises much more slowly. They cross at a marked point labelled break even, with a help line dropping to the axis. Along the bottom stand the words cradle, use and gate. BREAK EVEN MANUFACTURE 0 FOSSIL ELECTRIC DISTANCE DRIVEN EMISSIONS CRADLE . USE . GATE
  • A test piece in a rig with four sensors and the reading written above A rectangular test piece stands in the middle with six violet lines across it. Four sensors sit at its corners, each joined by a cool line to a small circle further out. Above the piece a panel shows a blue trace being recorded, and a glowing line joins the panel to the piece. A measurement line spans the piece. Along the bottom stand the words repeatable, written down and dated. REPEATABLE . WRITTEN DOWN . DATED
  • An electric aircraft seen from the front with battery bays in the wings An aircraft drawn from the front in thin outline. A propeller turns above the nose and a glowing line runs up into it. Each wing carries eight battery bays marked in violet. A measurement line spans the wingspan. Along the bottom stand the words energy, mass and reserve. ENERGY . MASS . RESERVE
A printer building an object layer by layer, with the layers enlarged beside it A gantry frame with a nozzle in the middle. A glowing line falls from the nozzle onto a stack of thin layers that grows narrower towards the top, the highest ones marked in violet. To the right a circle enlarges six layers so the bonding between them can be seen. A measurement line spans the base. Along the bottom stand the words layer, adhesion and tolerance. LAYER . ADHESION . TOLERANCE
Additiv tillverkning på nära håll
Additive manufacturing at scale. The part is built up pass by pass, so what it costs follows the volume and not the shape.

07. Making the part

Printed and laid up, not machined from a block

Additive manufacturing changed which shapes are affordable, and composite lay up changed which shapes are light. Together they moved the constraint from what a machine can cut to what a part can be asked to do.

Both bring their own failure modes, and both are well covered in the record: layer adhesion in one, fibre direction and the resin system in the other. A prototype that fails at a layer boundary fails for a reason someone already wrote down.

Neither replaces machining. What they do is move the decision earlier: you now choose the process while the part is still a sketch, and that choice sets what the part can weigh and what it can cost.

Two emission lines crossing at the point where the electric vehicle pays back A chart with distance along the bottom and emissions up the side. A cool line starts at zero and rises steeply. A violet line starts higher, because building the battery costs something, and rises much more slowly. They cross at a marked point labelled break even, with a help line dropping to the axis. Along the bottom stand the words cradle, use and gate. BREAK EVEN MANUFACTURE 0 FOSSIL ELECTRIC DISTANCE DRIVEN EMISSIONS CRADLE . USE . GATE
Förnybar kraft i landskapet
Wind turbines against the sun. What the grid runs on decides how far a battery has to travel before it has caught up.

08. What the vehicle owes

A battery starts the race behind

Building a pack costs something before the vehicle has moved a metre. An electric vehicle therefore begins with a debt, and pays it back over distance. Where the two lines cross depends on the cell, on the grid that charges it, and on how far the thing actually travels.

That is an argument that should be made with a measurement and not with a feeling. What the pack is worth after the vehicle is done with it belongs in the same calculation, and it is usually left out.

The four questions

Asked of every one of them

Whatever the shape, the first month asks these. The answers differ. The questions do not.

One cell becoming a module and then a pack Three drawings side by side joined by arrows. On the left a single cell with two terminals. In the middle a module holding five cells in violet. On the right a pack holding twelve modules in a grid, with a glowing line rising from it. The words cell, module and pack stand under each. Along the bottom stand the words chemistry, thermal path and serviceability. CELL MODULE PACK CHEMISTRY . THERMAL PATH . SERVICEABILITY

How much can it carry

Energy on board, and what carrying it costs in mass and in volume you then have to move.

A charging curve where power falls as the cell fills A chart with two axes. A blue line holds high and then falls away in steps as it moves right, and a violet line rises to meet it. A charging connector stands to the left of the chart with a glowing lead into it. Along the bottom stand the words taper, temperature and time at plug. POWER STATE OF CHARGE TAPER . TEMPERATURE . TIME AT PLUG

How fast can it be filled

The interface, the standard that governs it, and the curve that decides what the number on the poster really means.

An electric motor seen end on, with the inverter beside it A motor drawn as concentric circles seen from the end. Twelve stator poles stand around the rim and eight rotor magnets sit inside them in violet. A glowing line runs from the motor to a power electronics box on the right with three cooling channels. A measurement line spans the motor diameter. Along the bottom stand the words stator, rotor and inverter. STATOR . ROTOR . INVERTER

Where does the heat go

Out of the cell, through the structure, into air or water. The path is the design, and it is decided early whether you decide it or not.

The life of a battery drawn as a ring with five stops Five circles stand around a faint ring, marked build, use, measure, reuse and recover. A glowing arc runs from the first towards the second. Below the ring a branch leads down to a smaller pack with three cells marked in violet. Along the bottom stand the words second life and material recovery. BUILD USE MEASURE REUSE RECOVER SECOND LIFE . MATERIAL RECOVERY

What happens after

Second life, recovery, and what the pack is still worth when the vehicle is finished with it.

The field

Six places the current already runs

None of these is a prototype. They are all in service somewhere today.

  • En laddstation för fordon
    Bays marked for electric vehicles, where the queue is for the connection and not the space.
  • Eldriven tung transport
    A trolleybus, which solves the battery problem by not having one.
  • Ett eldrivet tåg
    Overhead line across a crossing. The oldest electric transport still carries the most.
  • En eldriven båt
    A solar electric passenger boat, where the water both cools and corrodes.
  • Ett eldrivet flygplan
    A solar aircraft on a lakebed, built around an energy budget rather than a cabin.
  • Förnybar kraft i landskapet
    Wind turbines, which decide how quickly a battery pays back what it cost to make.
An opened envelope under an arc of light An envelope stands open in the middle with two lines of text visible, one of them violet. An arc of light curves over it from left to right and ends in a point. Above stands two paragraphs is enough, below stands it reaches the person who would build it. TWO PARAGRAPHS IS ENOUGH IT REACHES THE PERSON WHO WOULD BUILD IT

Something in this list is yours

Tell us which one and what worries you about it. If the record says it is taken, you will hear that on the call.

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