EVEA Solutions offers you, through its mechanical engineering service, various services to meet the complex challenges of mechanical integration within electric vehicles.
Project study: A well-defined need generates a successful project. Our objective is to identify together the different strategic issues of the need, the final product ‘environment, the constraints of planning, weight, bulk, the estimation of costs and deadlines, and the coordination between the different stakeholders ( internal or external).
Mechanical design: We support you in the design of systems, products or mechanical components using CAD software to create 3D models, plans and technical drawings, but also in the choice of materials according to design, performance and of cost.
Stress and Strain Analysis: The torque provided by electric motors requires an assessment of the strength, durability and safety of mechanical components. An aspect too often ignored.
As part of the design of electric powertrains, we can carry out analyzes of stress, fatigue, material resistance, structural dynamics and mechanical constraints imposed by electric motors and transmission elements. Well-thought-out mechanical design is crucial to ensure system safety, reliability and performance.
Manufacturing of prototypes: Thanks to our partners in France and Europe, EVEA Solutions offers its customers a wide choice of techniques for manufacturing prototypes (machining, laser/water jet cutting, sheet metal bending, injection, foundry, printing 3D)
Prototyping and testing: EVEA Solutions has an integration service (link) in which product prototypes are assembled and tested. The idea is to support you in the assembly of prototypes and/or series heads of the product but also to carry out validation, performance and durability tests.
Maintenance and repair: Contrary to popular belief, electric-powered systems and vehicles require periodic mechanical maintenance to ensure that mechanical components, such as bearings, seals, belts and gears, are functioning properly. Regular inspection is essential to ensure the durability of the system.
Safety and compliance: EVEA Solutions can also support you in all phases of certification to ensure that designs comply with safety standards and regulations in force (machine/vehicle standards).
In summary, the electric motor alone represents a mechanical element in its own right with many facets such as motion transmission, speed reduction, electric braking and maintenance. So many elements requiring special attention during their design.
This combination of mechanics, electricity and electronics is essential for all modern applications, from electric vehicles to industrial machines.
EVEA Solutions develops numerous custom electronic products to interface various components of electric powertrains with the existing systems of our clients' vehicles and machinery. This department is absolutely crucial in the context of retrofits and electric conversions.
Here are some key points related to electric propulsion and its integration with electronics:
Electronic Control: Electric motors are generally controlled by electronic circuits, such as variable frequency drives (VFDs) or microcontrollers. These electronic devices regulate the speed, torque, and direction of rotation of the motor.
Automation: Electric propulsion systems can be integrated into automated systems. For example, in a production line, electronically controlled electric motors can move products, perform lifting operations, etc.
Energy Efficiency: The use of electronics to control electric motors optimizes energy efficiency. Control devices can adjust the power supplied to the motor based on its needs, reducing energy consumption.
Electric Vehicles: In the context of electric vehicles, electric propulsion is essential. Electric motors power the vehicle's wheels, and onboard electronics manage energy distribution, regenerative braking, battery management, etc.
Renewable Energies: Renewable energies, such as solar and wind power, also use electric propulsion to convert mechanical energy into electricity. Wind turbines and solar panels often employ electric motors to track the direction of the wind or sun.
Industrial Applications: Industry widely uses electric propulsion for conveyors, machine tools, pumps, fans, and many other applications. Electronics enable adjusting the speed and operation of these motors based on production needs.
In summary, electric propulsion associated with electronics offers precise control and high energy efficiency in a wide range of industrial, commercial, and residential applications. It plays a central role in reducing energy consumption and transitioning to more sustainable solutions.
EVEA Solutions has an in-house department dedicated to the programming and configuration of electric traction components (inverters, chargers) as well as accessory controllers and Human Interface Modules (junction boxes, control screens, ECUs, CAN, CANopen interfaces).
Here are some key points regarding the programming of electric propulsion:
Microcontrollers and Microprocessors: Electric motors are typically controlled by programmable microcontrollers or microprocessors. These electronic chips execute the computer code that manages the motor's operation.
Programming Languages: Various programming languages are used to program electric motors, depending on the application. Commonly used languages include C, C++, Python, and languages specific to industrial programmable logic controllers (PLCs) such as ladder logic.
Speed and Position Control: Programming allows adjusting the rotation speed and position of the electric motor according to the application's needs. Proportional-Integral-Derivative (PID) control algorithms are often used to maintain the desired speed and position.
User Interface: For consumer applications such as electric vehicles, industrial machinery, or robots, the user interface is a crucial aspect of programming. Touchscreens, mobile applications, or remote controls can be used to interact with the electric motor.
Communication Networks: In complex systems, programming may include managing communications with other system components via communication networks such as the Controller Area Network (CAN bus), Modbus, Ethernet, or wireless protocols like Wi-Fi or Bluetooth.
Safety and Redundancy: Electric propulsion programming must consider safety considerations. In critical applications, redundancy mechanisms and safety protocols must be implemented to ensure proper operation and reliability.
Energy Management: Programming may also include energy management, especially regulating power consumption to optimize energy efficiency and extend battery life, particularly in portable applications or electric vehicles.
Embedded Programming: In many applications, programming is embedded in the microcontroller or electronic system associated with the electric motor. This means that the computer code runs locally, allowing real-time responses.
In summary, programming for electric propulsion is a key element to control, automate, and optimize the operation of electric motors in a variety of applications, ranging from consumer devices to industrial systems. It enables customization of the motor's behavior according to the application's needs and harnesses the full potential of electric energy.
EVEA Solutions offers, in close collaboration with our mechanical, electronic, and wiring design services, an electric powertrain integration service. The role of the integration service is to act as the project management interface among all stakeholders (mechanical, electronic, wiring, automation, etc.), overseeing schedules and various normative aspects.
Although often overlooked, this essential service aims to establish the framework for the project's progression and provide an overall view of the distribution of roles among the stakeholders.
Here is an overview of this process:
Design and Specifications: It all begins with defining the needs and specifications of your system. You must determine the power, speed, torque, and other characteristics required for the electric motor.
Choice of Electric Motor: Once the specifications are established, you select the appropriate type of electric motor for your application. Common choices include direct current (DC) motors, alternating current (AC) motors, stepper motors, etc.
Mechanical Design: The mechanical design of the system is crucial. It involves creating supports, shafts, gears, or any other mechanism necessary to connect the electric motor to the load.
Electrical Integration: You need to wire the electric motor to the rest of the system. This may include connecting the power supply, the controller (if any), and appropriate sensors.
Electronic Control: In many applications, the electric motor is electronically controlled to regulate speed, direction, torque, etc. This requires programming control circuits or microcontrollers.
Safety: It is essential to consider safety considerations when integrating electric propulsion, especially if the system is intended for public use. Safety devices such as emergency stop switches and speed limits may be necessary.
Testing and Validation: Once integration is complete, rigorous testing and validation are necessary to ensure that the system operates correctly and safely.
Maintenance and Updates: Like any system, integrated electric propulsion requires periodic maintenance to ensure proper operation. Additionally, updates may be necessary to improve performance or add new features.
Integrating electric propulsion can be complex and varies significantly depending on the specific application. It is often wise to work with engineers or specialists in the field to ensure that integration is done optimally and in compliance with prevailing standards.
The electric conversion of industrial and agricultural machinery is emerging as a major trend in the pursuit of sustainability and energy efficiency. This shift towards electrification offers significant advantages for both the environment and industrial and agricultural operations.
Electric motors are generally more efficient than their internal combustion counterparts. The conversion to electric power in industrial and agricultural machinery allows for a more efficient use of energy, resulting in reduced operational costs and lower energy consumption to accomplish the same tasks.
In addition to their environmental benefits, electric motors are generally quieter than internal combustion engines. This reduction in noise levels creates a more pleasant working environment while minimizing sound impacts on surrounding communities.
In conclusion, the electric conversion of industrial and agricultural machinery represents much more than a mere technological evolution. It is a decisive step towards an industry and agriculture that are more environmentally friendly, efficient, and sustainable. The economic and environmental benefits of this transition create a positive momentum, fostering innovation and propelling industrial and agricultural sectors towards a greener future.