#Battery assembly for electric vehicles

[semcoinfratechworld]

EVs Powered by Battery Assembly Innovations

Electric vehicles (EVs) rely heavily on their power batteries, which act as the vehicle's engine by supplying the energy required for propulsion. Guaranteeing the longevity, functionality, and safety of these power batteries is crucial. As a result, the assembly of power batteries is now a key component in the electric vehicle sector. In this piece, we will examine the main procedures for assembling power batteries, as well as the difficulties encountered and creative solutions that underpin this vital area of EV technology.

Key Processes of Power Battery Assembly

Assembling power batteries is a difficult process that requires many crucial steps. These consist of:

Assembly of High and Low Voltage Connectors: Power battery packs need to have many high and low-voltage connectors assembled safely. Special sensor-type and gun-type tools ensure tightening and torque control.

Installation of High-Voltage Wiring Harnesses: To prevent hazardous conductive metal paths, assemblies involving high-voltage wiring harnesses require careful insulation. Safety precautions are in place to keep employees safe from electric shocks.

Installation and Connection of High-Pressure Copper Bars: Conduction between battery modules is facilitated by high-voltage copper bars. Short circuits may arise from carelessness during assembly, underscoring the significance of exact and secure assembly procedures.

Installation of Modules: Battery packs are made up of several battery modules, each of which has power cells. These modules must be installed correctly to avoid deformation or damage while in use.

Top Cover Installation: Power battery packs usually use aluminum cases to maximize weight and efficiency. These cases need to be assembled carefully because dozens of bolts need to be tightened in a precise order to guarantee even stress distribution.

Assembly Focus and Solutions

Power battery assembly presents some difficulties, all of which must be solved creatively:

Poor contact and overheating: They can arise from overcurrent problems at assembly points. Electric tools with sensor-type functions are used to continuously monitor the assembly process, guaranteeing proper torque and averting overheating.

Insulation Issue: Assembling and maintaining battery modules frequently happens in real-time, increasing the possibility of electrical shock. For the safety of the workforce, insulation tools and stringent compliance with insulation regulations are essential.

Problem with Residual Torque: Torque attenuation can occur at some assembly points, including connector assembly stations and upper cover stations. Digital torque wrenches and careful bolt-tightening sequence are two tools that help preserve quality.

Tightening Order Issue: Precise tightening and even stress distribution are necessary for large parts, such as battery pack covers. When combined with assembly tools, visual positioning systems improve tightening process accuracy and efficiency.

Prospects of Future Power Battery Assembly Technology

Power Battery Assembly: They will continue to innovate in the future. Advanced tools and automated assembly systems are being developed by EV manufacturers to improve product quality, data traceability, and assembly efficiency.

Wireless Power Tools: When torque requirements are not too high, portable, high-performance wireless power tools are becoming more and more popular for assembling power batteries. They offer flexibility and precision.

Automated Assembly Systems: These systems are being used to increase assembly quality, decrease errors, and optimize production processes. These systems lower expenses while increasing efficiency.

Conclusion

An essential component of electric vehicle manufacturing, power battery assembly affects longevity, performance, and safety. Innovations in assembly techniques and equipment are essential to meet the high standards that buyers expect as the EV market develops. Greater efficiency, accuracy, and safety are anticipated in power battery assembly in the future, which will support the market's ongoing expansion for electric vehicles.

[erik500w]

72V 35Ah DIY lithium battery pack assembly process

[rjzimmerman]

Excerpt from this story from Nation of Change:

China’s largest automaker, BYD, is selling its Dolphin hatchback EV for a low-low $15,000, complete with a 13-inch rotating screen, ventilated front seats, and a 260-mile range. Here in the U.S., you have to pay more than twice that price for the Tesla Model 3 EV ($39,000) with lower tech and only 10 more miles of driving range. In case $15K beats your budget, the Dolphin has a plug-in hybrid version with an industry-leading 74-mile range on a single charge for only $11,000 and an upgrade with an unbeatable combined gas-electric range of 1,300 miles. Not surprisingly, EVs surged to 52% of all auto sales in China last year. And with such a strong domestic springboard into the world market, Chinese companies accounted for more than 70% of global EV sales.

It’s time to face reality in the world of cars and light trucks. Let’s admit it, China’s visionary industrial policy is the source of its growing dominance over global EV production. Back in 2009-2010, three years before Elon Musk sold his first mass-production Tesla, Beijing decided to accelerate the growth of its domestic auto industry, including cheap, all-electric vehicles with short ranges for its city drivers. Realizing that an EV is just a steel box with a battery, and battery quality determines car quality, Beijing set about systematically creating a vertical monopoly for those batteries — from raw materials like lithium and cobalt from the Congo all the way to cutting-edge factories for the final product. With its chokehold on refining all the essential raw materials for EV batteries (cobalt, graphite, lithium, and nickel), by 2023-2024 China accounted for well over 80% of global sales of battery components and nearly two-thirds of all finished EV batteries.

Clearly, new technology is driving our automotive future, and it’s increasingly clear that China is in the driver’s seat, ready to run over the auto industries of the U.S. and the European Union like so much roadkill. Indeed, Beijing switched to the export of autos, particularly EVs, to kick-start its slumbering economy in the aftermath of the Covid lockdown.

Given that it was already the world’s industrial powerhouse, China’s auto industry was more than ready for the challenge. After robotic factories there assemble complete cars, hands-free, from metal stamping to spray painting for less than the cost of a top-end refrigerator in the U.S., Chinese companies pop in their low-cost batteries and head to one of the country’s fully automated shipping ports. There, instead of relying on commercial carriers, leading automaker BYD cut costs to the bone by launching its own fleet of eight enormous ocean-going freighters. It started in January 2024 with the BYD Explorer No. 1, capable of carrying 7,000 vehicles anywhere in the world, custom-designed for speedy drive-on, drive-off delivery. That same month, another major Chinese company you’ve undoubtedly never heard of, SAIC Motor, launched an even larger freighter, which regularly transports 7,600 cars to global markets.

Those cars are already heading for Europe, where BYD’s Dolphin has won a “5-Star Euro Safety Rating” and its dealerships are popping up like mushrooms in a mine shaft. In a matter of months, Chinese cars had captured 11% of the European market. Last year, BYD began planning its first factory in Mexico as an “export hub” for the American market and is already building billion-dollar factories in Turkey, Thailand, and Indonesia. Realizing that “20% to 30%” of his company’s revenue is at risk, Ford CEO Jim Farley says his plants are switching to low-cost EVs to keep up. After the looming competition led GM to bring back its low-cost Chevy Bolt EV, company Vice President Kurt Kelty said that GM will “drive the cost of E.V.s to lower than internal combustion engine vehicles.”

So, what does all this mean for America? In the past four years, the Biden administration made real strides in protecting the future of the country’s auto industry, which is headed toward ensuring that American motorists will be driving $10,000 EVs with a 1,000-mile range, a 10-year warranty, a running cost of 10 cents a mile, and 0 (yes zero!) climate-killing carbon emissions.

Not only did President Biden extend the critical $7,500 tax credit for the purchase of an American-made EV, but his 2021 Infrastructure Act helped raise the number of public-charging ports to a reasonable 192,000, with 1,000 more still being added weekly, reducing the range anxiety that troubles half of all American car owners. To cut the cost of the electricity needed to drive those car chargers, his 2022 Inflation Reduction Act allocated $370 billion to accelerate the transition to low-cost green energy. With such support, U.S. EV sales jumped 7% to a record 1.3 million units in 2024.

Most important of all, that funding stimulated research for a next-generation solid-state battery that could break China’s present stranglehold over most of the components needed to produce the current lithium-ion EV batteries. The solution: a blindingly simple bit of all-American innovation — don’t use any of those made-in-China components. With investment help from Volkswagen, the U.S. firm QuantumScape has recently developed a prototype for a solid-state battery that can reach “80% state of charge in less than 15 minutes,” while ensuring “improved safety,” extended battery life, and a driving range of 500 miles. Already, investment advisors are touting the company as the next Nvidia.

But wait a grim moment! If we take President Donald Trump at his word, his policies will slam the brakes on any such gains for the next four years — just long enough to potentially send the Detroit auto industry into a death spiral. On the campaign trail last year, Trump asked oil industry executives for a billion dollars in “campaign cash,” and told the Republican convention that he would “end the electrical vehicle mandate on day one” and thereby save “the U.S. auto industry from complete obliteration.” And in his victory speech last November, he celebrated the country’s oil reserves, saying, “We have more liquid gold than anyone else in the world.”

[scrumptiousbeardturtle-blog1]

Car Parts and Key Components: Proper Uses that Every Beginner Driver Should Know

Transporting your car can be daunting task, but it doesn’t have to be. A well-planned auto transport process making sure your car's safety from start to finish. With a reliable car carrier service like San Jose auto transport, rest assured your car will be delivered to your doorstep on-time.

This guide will provide you necessary information and useful tips about choosing a reliable auto transport service, common car parts, and basic function of your vehicle for safe driving journey.

Car Parts and It's Basic Function

This guide will shed you light with the common car parts and its basic functions for maintaining your car for efficient running condition. From the engine to the brakes, each part plays an important role. Get ready to gain confidence in your driving journey.

The engine generates power, while the transmission transfers that power to the wheels.

Brakes are important for stopping, so understanding how they work will guarantee safety and quickly respond to any unforeseen situations.

The battery powers electrical systems and starts the engine.

Familiarity with fluid levels, such as oil and coolant, prevent overheating and engine damage.

Learning about tire pressure helps maintain traction and safety on the road.

Proper knowledge of these common car parts are important for responsible car owner and safe driving practices.

Today's vehicles are complex machines with many interconnected systems and components. Vehicle owners who understand these simple parts can maintain their cars better and talk effectively with mechanics.

Car Cooling Systems:

Engine and Power-train components

Cooling and exhaust systems

Starting and charging systems

Fuel delivery mechanisms

Braking and steering assemblies

Suspension components

Heating and air conditioning

The engine acts as the vehicle's heart and converts fuel into mechanical energy through controlled combustion. Multiple precision components like the engine block, cylinder heads, camshafts, and crankshaft work together harmoniously.

Supporting systems are equally crucial. The cooling system regulates optimal operating temperatures, and the exhaust system handles waste gasses. The battery and alternator power the starting and charging system, which supplies electrical energy to run the engine and vehicle accessories.

This knowledge helps new car owners during routine maintenance and unexpected problems.

Car owners who understand simple car parts can:

Identify potential problems early

Schedule appropriate maintenance

Make informed repair decisions

Communicate clearly with service professionals

Maintain vehicle value through proper care

The drive-train moves power from the engine to the wheels. The braking system creates friction to stop safely. These systems collaborate with steering and suspension components to provide safe, comfortable transportation.

Important Functions of Car Engine

Your car's internal combustion engine transforms chemical energy into mechanical power through a precise sequence of events.

A well-maintained engine runs smoothly and improves your vehicle's performance and longer engine life.

Regular Engine Maintenance Schedule:

Check spark plugs every 30,000 miles

Monitor fluid levels monthly

Inspect air filters regularly for debris

Clean battery connections at the first sign of corrosion

Your engine's combustion chamber acts as a powerhouse that combines fuel and air to generate energy. The spark plug ignites the compressed fuel-air mixture and creates a controlled explosion that moves the pistons. A timing belt keeps all components in perfect sync during this sequence.

Power flows from the combustion chamber through several key steps:

Piston movement converts explosive force to linear motion

Crankshaft changes linear motion to rotational force

Flywheel smooths the power delivery

Transmission system directs power to wheels

A network of components prevents your engine from overheating. The radiator and water pump work together to circulate coolant through passages around the cylinders. Regular inspection of this temperature management system helps avoid repairs that can get pricey.

Your engine needs proper fluid levels to perform at its best:

Engine oil (check monthly)

Coolant

Brake fluid

Power steering fluid

Spark plugs play a vital role in the combustion process. Engine problems develop rapidly if they malfunction. You should inspect them regularly and replace them according to manufacturer specifications.

Understanding basic car parts and key components is important for any beginner driver in San Jose. This knowledge helps you maintain your vehicle and recognize issues early on. Remember the importance of the engine, brakes, and tires, as these are important parts of your vehicle for safe driving.

With this guide, you now have the tools to feel more confident behind the wheel. Always keep learning and be familiarized with every parts of your vehicle.

For more tips on finding a trusted service like auto transport company California, keep exploring our blog.

[reasonsforhope]

The U.S. Department of Treasury’s gift to electric-vehicle shoppers (and global automakers) for the new year was to make many more EVs and plug-in hybrids eligible for the federal tax subsidy of up to $7,500 — including vehicles built outside North America — as long as drivers lease them or buy used rather than buy new.

EV credits and [rules] took effect Jan. 1.

One category extends the former credit of up to $7,500 for consumers buying new EVs and PHEVs, but it puts new limits on vehicle price and buyer income and will soon add requirements for the sourcing of EV batteries and materials. Additionally, since August [2022], it has required that the vehicles be assembled in North America.

A second is a new credit of up to $4,000 for buyers of used EVs.

A third is a “commercial” credit for businesses acquiring EVs. It offers up to $7,500 for light-duty vehicles (under 14,000 pounds) and up to $40,000 for heavier vehicles. Significantly, the commercial credit does not have the origin, price or other restrictions of the credit for consumer buyers.

On top of all that, the Department of Treasury guidance released at the end of December allows the less restrictive commercial credit to also apply to vehicles leased by consumers; that means most plug-in and fuel-cell EVs currently on the market can qualify, including those built in Europe or Asia. The credit goes to the leasing company — the vehicle owner — but it can be passed to the consumer in the form of lower lease payments.

The new federal rules do not affect state and local subsidies available for EV buyers [which may be able to get you even more savings].

-via Cars.com, January 12, 2023

[iww-gnv]

DETROIT, Sept 29 (Reuters) - Ford Motor (F.N) Chief Executive Jim Farley blasted United Auto Workers leaders on Friday, saying they were holding up a new U.S. labor agreement hours after the UAW escalated the strike that is now in its third week, with the companies and workers far apart on their demands. UAW President Shawn Fain on Friday expanded the first-ever simultaneous strike against the Detroit Three, ordering workers to walk off the job at Ford's Chicago assembly plant and GM's (GM.N) Lansing, Michigan, assembly plant. He said Stellantis was spared after last-minute concessions by the Chrysler parent. Farley's comments were unusually sharp in the middle of an ongoing negotiation, saying the union was holding the company "hostage" with demands that "could have a devastating impact on our business." He said the dispute centered around wages and benefits at new electric vehicle battery plants that have yet to start production. “I don’t know why Jim Farley is lying about the state of negotiations," Fain said in a statement responding to the Ford CEO. "It could be because he failed to show up for bargaining this week, as he has for most of the past ten weeks." The union continued its deliberate approach to the strike, choosing to walk out of just two additional assembly plants - rather than the sweeping impact of a walkout at the Detroit Three's most profitable plants that make pickup trucks. In addition, the union is trying to conserve a limited strike fund that may be strained by additional strikes at Mack Trucks facilities and Detroit-area casinos that are also represented by the UAW.

[mothshrub]

Today I Learned encouraging stuff about electric vehicles and the whole 'but the batteries are worse than gas cars!' talking point.

The punchline: they actually aren't when you account for gas cars' tailpipe emissions. Over the car's life cycle, electric cars are better.

Source: EPA.gov EV Myth Debunking page

"Above, the blue bar represents emissions associated with the battery. The orange bars encompass the rest of the vehicle manufacturing (e.g., extracting materials, manufacturing and assembling other parts, and vehicle assembly) and end-of-life (recycling or disposal). The gray bars represent upstream emissions associated with producing gasoline or electricity (U.S. mix), and the yellow bar shows tailpipe emissions during vehicle operations."

[stevebattle]

GERO the GE Robot (1986) by Walt Disney Imagineering and General Electric Research & Development Center. GERO would ride around Future World a large scooter. “ “GERO” (short for “GE RObot”), is the newest robot to join the Horizons cast… and he’s destined to become one of Epcot’s most beloved characters. “GERO is probably the most sophisticated entertainment robot in the world,” says Dave Fink of General Electric. Designs for GERO originated at Walt Disney Imagineering in California. Veteran animator Xavier “X” Atencio created the inspirational drawings, using classic Disney character styling and proportions. GERO emerged from the drawing board as a fun-loving, friendly teen-ager – complete with a sporty scooter with room for riders! “The next step was to add the detailing that would give the robot a machined, hi-tech look,” says Designer Gil Keppler. At the Walt Disney Studios, artisans sculpted the robot in plaster, then shipped it to Walt Disney World where its Lexan body was fabricated, assembled, and painted in metallic silver & gold. As for the vehicle color… well, it just had to be red. After all, GERO’s a sporty guy! While GERO’s outward appearance was shaping up in Florida, scientists and technicians at the General Electric Research & Development Center were busily assembling the robot’s inner workings. Included in the 900-pound mountain of electronics are linear stepping motors, field effect transistor brakes, pulse-width modulated drives, incremental optical shaft encoder, fiber optics, laser disc player, 160 watts of biamped audio power and nine batteries – all controlled by 19 microcomputers! Yet with all that hi-tech hardware, there was one thing GERO still didn’t have – an education. It was time to go to school. At the GE R&D Center, computer technicians spent weeks raising the robot’s IQ from zero to GERO. By graduation time, GERO had learned to shake hands, wave goodbye, drive his scooter, converse and sing songs! He was ready to meet his public.” – Disney’s Exotic, Robotic Cast: “GERO” steals the show at EPCOT center, by Tom Fitzgerald.

[addressadvisors]

Why do all electric vehicle companies occupy Warehouse and Industrial space in Hosur?

With the electric buzz that has taken the nation by storm, the Government is planning to develop EV parks in the same line as SEZ and pharma parks across the country. The EV park aims to house majority original equipment manufacturers, battery manufacturers, and charging infrastructure developers at one place. With the vision to develop an entire ecosystem at one same place, the Government plans to offer plug-and-play business models to EV industries who will set up their units in these parks. One such park is located in north western districts of Tamil Nadu, just across the Karnataka border from Bengaluru, which houses a number of new-age EV companies, such as, Ather Energy, Ola Electronics, Simple Energy, among others.

The Rise of Hosur Several factors have helped the Hosur belt boom with several big-ticket projects and investments in the region. The cluster witnessed two substantially high profile investments in the last couple of years, with Tata electronics setting up a ₹5,000-crore mobile components plant at Udhanapalli, and Ola, a ₹2,500-crore electric vehicle (EV) plant at nearby Pochampally. These massive investments triggered the new EV boom in Hosur, with EV companies preferring Hosur for putting up their manufacturing units given a competent ancillary supplier network, proximity to Bengaluru where corporate offices of these companies are located, plus amicable and skilled labour force in two-wheeler, automotive, and electronics segment.

Well-oiled Supply-chain Network The region is equipped with a strong supply-chain ecosystem, making it easier for the companies to locally source components necessary for manufacturing and assembly. This, in turn, would help us in improving cost and time efficiency for the businesses. Moreover, companies are prompting tier-2 suppliers to move their base to Hosur area, to make smaller components in the close vicinity to further add to the efficiency.

Financial SOP and Easier Admittance EV companies in the Hosur area are upheld by EV policy contrived by Tamil Nadu Government. The policy is drafted to support EV companies with repayment of SGST for electric vehicle producing, capital appropriation for battery fabricating, business motivation as far as repayment of EPF for a time of one year, exclusion from instalment of Electricity Tax till 2025 and 100 percent stamp obligation exception.

Proximity to Bengaluru As most of the corporate offices are located in Bengaluru, the first preference of companies is to put up a plant within a comfortable driving distance from head office. As most of the senior employees and mid-level management sit at the head office, most of the companies want employees to be able to move between the office and the plant in an hour or so maximum. For instance, Ather Energy corporate office is located in Koramangala, which is 60 minutes away from the Ather Energy plant in Hosur. Moreover, the connection via Electronics city flyover helps cut through the traffic, which was initially the pain point of employees moving between Koramangala and Whitefield, where Ather Energy plant was located.

Availability of Land and Scalability Scope Given the area related bottleneck in Bengaluru, it is essential for EV companies or any other manufacturing units to look into areas nearby that can accommodate projected production capacity and growth plans. Given, land investments are not made again and again, it is always advisable for the companies to take up the area based on the most optimistic business projections. With the same thought, Ather Energy Hosur plant is spread across 300,000 Sq. Ft. with capacity to produce 1,10,000 scooters annually. Ather Energy envisions that the plant will serve as Ather Energy’s national manufacturing hub, catering to demand from across the country. Moreover, the plant is nearly 10 times the capacity of the Whitefield, Bengaluru, plant.

Hosur Historic Precedence Within the close proximity to Bengaluru, Hosur area has historically been a dominant space for two wheeler, automotive, and electronics business segments. Given that EV is primarily an amalgamation of these three segments, it is therefore a natural choice for EV companies to develop manufacturing units in the Hosur area. Moreover, with established and consistent access to power, land, and labour relevant to the industry, Hosur is the first choice of investment. Furthermore, a lot of fossil-fuelled automotive industries are also expanding into the EV segment. This has prompted an easy transition for existing automotive companies in the area. Also, as Tamil Nadu has over 800 engineering colleges, the state offers an intellectual and skilled labour pool ensuring steady stream for the workforce.

Amicable Labour and Supportive Workforce In the area, it is widely noted that the kind of labour unrest Bengaluru witnesses is not seen in the Tamil Nadu north western districts, which are barely an hour away from each other. The most plausible reason for this could be the existential automotive businesses in the Hosur area, unlike Bengaluru, where labourers are experiencing the automotive industry for the first time. In Hosur, both industry and labour have matured, and the companies have learnt that exploitative practices are rather counter-productive. Therefore, most of the EV companies find this a huge draw in making investment decisions in the Hosur area.

Hosur Meteoric rise and the way ahead Given the reasons above along with a network of highways facilitating logistics of movement and the welcoming policies set by the Tamil Nadu Government for automotive companies, Hosur belt is emerging as an industrial bowl for the electric vehicle manufacturers. Tata, Delta, Ola Mobility, Ather Energy, and Simple Energy are some of the big names in the electronics and electric vehicle (EV) sectors that have made Hosur and the surrounding districts their home in the past few years.

Along with growing awareness and spiralling petrol prices, the demand for EV is set to increase significantly in the coming years. As per the data, In January 2022, overall high-speed EV two-wheeler registrations rose to 27,563 units as compared to 24,725 units in December 2021. To match the rising demand, manufacturers have to up their capacity, for example Ather Energy recently commissioned its second facility in Hosur to increase its capacity from 1,20,000 units to 4,00,000 units. Ola Electric has set out to build the world’s largest EV facility with an initial annual capacity of two million units. Furthermore, TVS has also decided to invest over 1,100 crores in the area for the new EV plant. If the cards are played right, this belt could further emerge as a global player given the fast adoption of EVs, especially in the two-wheeler segment.

[materialsscienceandengineering]

There's a reason airlines won't let you put your laptop in your checked luggage; the lithium-ion battery poses a serious fire hazard. But why? Lithium is incredibly reactive. For instance, pure lithium violently interacts with seemingly innocuous water, releasing heat and forming highly flammable hydrogen. This reactivity, however, is exactly why lithium makes a great material for batteries, and why it is a critical mineral for the green energy transition. Lithium-ion batteries are widely used in electric vehicles. Plus, they can store energy produced by renewable resources like solar and wind. In recent years, lithium demand has skyrocketed. Primary sources for lithium like pegmatites and volcanic clays are well understood, but finding other stores that are safe and economical to exploit would be helpful. To that end, a team led by researchers from West Virginia University is exploring whether previous industrial operations (e.g., mine tailings or drill cuttings) could serve as a source of additional lithium without generating new waste materials. Shailee Bhattacharya, a sedimentary geochemist and doctoral student working with Professor Shikha Sharma in theIsoBioGeM Lab at West Virginia University, will present the team's findings next week during the European Geosciences Union (EGU) General Assembly 2024.

Read more.

[mariacallous]

Elon Musk hasn’t been sighted at the picket lines in Missouri, Ohio, or Michigan, where autoworkers are striking against the Big Three US carmakers. Yet the influence of Musk and his non-unionized company Tesla have been everywhere since the United Auto Workers called the strike last week. In some ways, Tesla—the world’s most valuable automaker by market capitalization—set the whole thing in motion.

Tesla’s pioneering electric vehicles kicked off a new era that has turned the entire auto industry on its head. In a scramble to compete with Tesla and make that transition, the legacy automakers targeted by the current strike, General Motors, Ford, and Stellantis, have each pledged billions in global investment and have begun dramatically restructuring their operations. For workers, the “green jobs” being created can be scarcer and worse paying. Electric vehicle powertrains have many fewer moving parts than conventional gas-powered ones, and so they require 30 percent fewer vehicle assembly hours, according to one estimate. Plants that make EV batteries are generally outside the core, unionized auto supply chain. The United Auto Workers has seen a dramatic drop in membership due to jobs moving outside the US—it lost 45 percent of its members between 2001 and 2022. A future with more electric vehicles could mean fewer union jobs overall. “This strike is about electrification,” says Mark Barrott, an automotive analyst at the Michigan-based consultancy Plante Moran.

The new assembly plants that the legacy automakers need to pull off the transition have been stood up mostly in US states hostile to union organizing, such as Kentucky, Tennessee, and Alabama. And because many of these plants are joint ventures between automakers and foreign battery companies, they are not subject to previous union contracts.

The UAW did not respond to a request for comment, but UAW president Shawn Fain told CNBC last week that the electric transition can’t leave workers behind. “Workers deserve their share of equity in this economy,” he said.

Tesla’s rise over recent years has also put ever-ratcheting pressure on the legacy automakers to cut costs. Including benefits, Musk’s non-unionized EV company spends $45 per hour on labor, significantly less than the $63 per hour spent in the Big Three, according to industry analysts.

Musk’s willingness to upend auto manufacturing shibboleths has also forced his legacy competitors to seek new efficiencies. Tesla led the way in building large-scale car casts, stamping out very large metal components in one go rather than making a series of small casts that have to be joined together. And it pioneered an automotive chassis building process that can be easily adapted to produce different makes and models.

Tesla’s Silicon Valley roots also helped it become the first automaker to envision the car as a software-first, iPhone-like “platform” that can be modified via over-the-air updates. And the company aims to automate more of its factories, and extract more of the materials it needs to build its batteries itself.

Tesla’s novel production ideas could soon lead the company to put even more pressure on legacy automakers. Musk said earlier this year that Tesla plans to build a new, smaller vehicle that can be made for half the production cost of its most popular (and cheapest) vehicle, the Model 3.

Musk says a lot of things, and many don’t come to pass. (The world is still waiting for the 1 million Tesla robotaxis promised by the end of 2020.) But Tesla has been disruptive enough to leave legacy automakers, including Detroit’s Big Three, “in a quest for capital,” says Marick Masters, who studies labor and workplace issues at Wayne State University's School of Business. Detroit’s automakers have made good money in the past decade—some $250 billion in profits—but also paid a significant chunk of it out in dividends. Pressure from Tesla and the EV transition it catalyzed has left them feeling as if they need every penny they can corral to keep afloat as the industry changes.

“They have little money to concede for union demands,” says Masters. The UAW’s wants include significantly higher wages, especially for workers who have joined the companies since their Great Recession and bankruptcy-era reorganizations, which left some with less pay and reduced pension and health benefits.

So far, the UAW has shown little patience for the idea that the automakers it is pressuring are cash-strapped and under competitive pressure. “Competition is a code word for race to the bottom, and I'm not concerned about Elon Musk building more rocket ships so he can fly into outer space and stuff,” UAW president Fain told CNBC last week when asked about pressure from Tesla. He has argued that production workers should receive the same pay raise received by auto executives over recent years.

When automakers have taken the opposite tack, insisting that they’re well capitalized and making plans to put them ahead of the electric car maker—well, that set up conditions for this strike too. The three American automakers are forecasted to make $32 billion in profits this year, a slight dip from last year’s 10-year high. “The more they toot their own horns about profitability, the more the union looks at them and says, ‘We want our rightful share,’” says Masters.

Tesla did not respond to a request for comment, but Musk has, in typical fashion, chimed in. He posted on X last week to compare working conditions at his companies with the competition, apparently seeking to turn the dispute he helped foment into a recruiting pitch. “Tesla and SpaceX factories have a great vibe. We encourage playing music and having some fun,” he wrote. “We pay more than the UAW btw, but performance expectations are also higher.” A UAW attempt to organize Tesla workers in 2017 and 2018, as the company struggled to produce its Model 3, failed. The National Labor Board ruled that Tesla violated labor laws during the organizing drive; the carmaker has appealed the decision.

[semcoinfratechworld]

Understanding the Working Module and Structure of Lithium-ion Batteries

As the backbone of modern energy storage solutions, lithium-ion batteries power everything from smartphones to electric vehicles. Their widespread adoption is fuelled by their high energy density, long life cycle, and lightweight design. In this blog, we delve into the working module and structure of lithium-ion batteries, offering an informative perspective on how they function and why they are so effective.

The Structure of Lithium-ion Batteries

At their core, lithium-ion batteries are composed of several key components that work together to store and release energy. These include:

1. Electrodes

Anode (Negative Electrode): Typically made of graphite, the anode stores lithium ions during charging and releases them during discharging.

Cathode (Positive Electrode): Made from lithium metal oxides, such as lithium cobalt oxide (LiCoO2) or lithium iron phosphate (LiFePO4), the cathode is where lithium ions are released during charging.

2. Electrolyte

The electrolyte acts as a medium, allowing lithium ions to flow between the anode and cathode. It is usually a liquid or gel containing lithium salts dissolved in an organic solvent.

3. Separator

The separator is a porous membrane that prevents direct contact between the anode and cathode while allowing ions to pass through. This ensures safety and prevents short circuits.

4. Current Collectors

Positive Collector: Made of aluminium foil, it collects electrons from the cathode.

Negative Collector: Made of copper foil, it collects electrons from the anode.

5. Battery Casing

The external casing protects the internal components from environmental factors and ensures mechanical stability.

How Lithium-ion Batteries Work?

The working module of a lithium-ion battery revolves around the movement of lithium ions between the anode and cathode through the electrolyte. This process can be divided into two main phases:

1. Charging Phase

When the battery is connected to a power source:

Lithium ions move from the cathode to the anode through the electrolyte.

Electrons flow externally from the cathode to the anode via the charging circuit.

These ions and electrons are stored in the anode, effectively charging the battery.

2. Discharging Phase

When the battery is in use:

Lithium ions flow back from the anode to the cathode through the electrolyte.

Electrons flow externally from the anode to the cathode, providing power to the connected device.

This reversible process of ion and electron movement is what enables the rechargeable nature of lithium-ion batteries.

Key Features of Lithium-ion Batteries

Understanding the structure and working of lithium-ion batteries highlights several features that make them ideal for various applications:

High Energy Density: These batteries store more energy in a smaller space compared to traditional batteries.

Lightweight Design: The use of lithium, a light metal, ensures minimal weight without compromising performance.

Low Self-Discharge Rate: Lithium-ion batteries lose very little charge when not in use.

Long Lifespan: They can withstand hundreds to thousands of charge-discharge cycles, making them cost-effective in the long run.

Applications of Lithium-ion Batteries

The versatility of lithium-ion batteries has made them indispensable across industries:

Consumer Electronics: Powering smartphones, laptops, and cameras.

Electric Vehicles (EVs): Providing energy for cars, buses, and even bicycles.

Renewable Energy Storage: Enhancing the efficiency of solar and wind power systems.

Medical Devices: Powering critical equipment like pacemakers and portable diagnostic tools.

Challenges and Innovations

Despite their advantages, lithium-ion batteries face challenges such as:

Thermal Runaway: Overheating can lead to fires or explosions.

Resource Dependency: Mining for lithium and cobalt poses environmental and ethical concerns.

Innovations like solid-state batteries and recycling technologies are addressing these issues, paving the way for more sustainable energy storage solutions.

Conclusion

The working module and structure of lithium-ion batteries showcase their engineering brilliance and efficiency. Their ability to store and deliver energy with minimal loss has revolutionized multiple industries, cementing their place as a cornerstone of modern technology. As research advances, the potential of lithium-ion batteries will only grow, enabling smarter, greener, and more energy-efficient solutions.

[bumblebeeappletree]

Nick Newman helped design a modular construction system so anyone with just a mallet and a drill can build their own home. Since co-founding U-Build in 2020, he has built— and watched others build— furniture, garden sheds, tiny homes, and full-sized houses, so it makes sense he’d use the flat-pack box system to turn the company work van into his full-time home.

[Watch our first video featuring Nick's U-Build universal home-build system, a CNC-cut flat-pack design anybody can assemble to make a home: • U-Build hands-on:... ]

According to Newman, "the U-Build construction system is something like if IKEA and LEGO had a baby. So, it's these big boxes that can be assembled with a mallet and a screwdriver. Effectively, you start out with your individual panels, which are cut with precision using a CNC machine, and it's designed with this kind of locking system so you can basically put the pieces together: it would always be on the 'right' configuration." Watch it at 25:45.

[Video timeline]

— Nick Newman out in London on his electric campervan: 00:10

— Explaining EV's lack of congestion charge in London: 00:20

— Charging the van in central London: 00:50

— Thunderstorm: 2:20

— Stealth setup: 03:00

— EV van conversion into vanlife camper: 3:30

— Conversion with U-Build boxes ("building blocks") timelapse: 3:42

— Explanation of a U-Build minimum unit of construction, the box: 03:50

— Kirsten interviews Nick Newman: 04:20

— U-Build's modularity put to the test inside a van: 05:10

— Locking system for drawers (inspired by the ones on commercial aircraft): 06:30 and 14:50

— Festival build out of U-Build blocks: 07:15

— Sink: 0832

— Current van living interior: 11:30

— Adapting working straps to vanlife: 12:00

�� Folding clothes: 13:05

— Hammock setup: 19:28

— At Stroud, Gloucestershire: 20:45

— U-Build's workshop under construction on an old empty factory: 21:30

— Describing U-Build as a self-build system: 25:45

— On using empty buildings: 22:10

— "People could stay in a house like this for really cheap": 22:15

— Warehouse spaces to solve housing emergencies? 22:30

— Out in Herefordshire: 36:28

— Student-built house with U-Build: 36:35

He started using the fully-electric Sprinter van as a temporary home while on overnight work trips. The U-Build system involves assembling CNC-cut, formaldehyde-free plywood boxes as building blocks which then bolt together to create a rigid frame for a structure.

The conversion cost him less than £2,000 (about $2,400, or €2,300). The system is entirely demountable, so the boxes can be reused over and over: it was easy for Newman to take the boxes he was working with daily and rearrange them in the van to build a bed, kitchen (U-Scrub), storage, and toilet (U-Poo).

Newman left a shared warehouse where he was paying £800 for a tiny, windowless bedroom for vanlife in central London, and because the van is electric, he doesn’t pay congestion charges (£15/day). He has tricked out the van to appear in drive mode so he can use the vehicle’s battery and air conditioning and heating while parked.

The U-Build (and Studio Bark) team recently bought an abandoned warehouse in Stroud (Gloucestershire) for less than the price of a tiny studio in London. While they decide what to do with the space, they have installed U-Build dwellings (built in a half day) to use as bedrooms and private offices. It’s the same model as the SHED Project, where they worked with a London-based guardian company to provide quick-build homes from U-Build kits to provide housing for those in need in exchange for building surveillance.

https://u-build.org/

https://www.instagram.com/ubuild/

Nick's YouTube channel: / @electric.vanlife

Here's our story covered by Autoevolution: https://www.autoevolution.com/news/th...

On *faircompanies: https://faircompanies.com/videos/u-bu...

[fundamentalreports]

How US EV Tax Credits are Driving a New Era for Automotive Policy

The US government is encouraging the production of electric vehicles (EVs) by offering tax credits to those that meet certain requirements for local content. This includes using minerals sourced from the US or its free trade partners and assembling at least 50% of the battery components in the US, Canada, or Mexico. The tax credit can reduce an EV buyer’s taxes by up to $7,500. This move signals…

[lucky3721]

Here is a van created to make you feel like you are still in the old cabin while parked at a wayside. This van has a gas-powered heater to keep you warm, a powerful fan to keep you cool and even a hideaway toilet! Complete with a sink and a fridge, this small kitchen also has an induction stove built into it. The bed space is a queen size, with a pull-out drawer directly underneath. This nomadic vehicle is equipped with solar panels and a DCDC Charger to keep all of its 4 12v batteries charged. As well as a shore power plug for when it's a bit cloudy and you don't feel like driving around. There is also a 28-gallon fresh water tank which can be put to use through the sink or the spigot installed near the fill point. With a grey water tank at 25 gallons. They both empty the bottom of the van, for convenience and stealth. With just about as many screws as you can see, this is mainly held together by Festool Dominos and Titebond Type 3 Wood glue. A beefy wooden domino-shaped dowel that takes the place of an otherwise squeaky bolt or screw. Ensuring this furniture will hold up to bumpy roads as long as you can hold onto the wheel.

Practically off the factory line with less than 500 mi to the engine. Grab this gem and take it out on an adventure before someone can claim your untold quests.

Contact us for more details, price is flexible and negotiable. Delivery will add miles to the vehicle, but distance isn't an issue by land.

Heater = Webasto 2500 gas-powered heater, temperature controlled. Automatic low gas sensor so it won't run you dry

Fan = Maxx fan deluxe dual-direction, temperature controlled

Electric (Victron)

- Multiplus 3000A ACDC inverter

4 GFCI outlets, 10 USB ports

- Tri smart DCDC Alternator charger

Charge your batteries while driving

- 150/50 Smart solar charger, Renology solar panels

Borrow some of the sun's energy to charge your batteries very quickly

- Cerbo Gx monitoring system

The brains behind the electrical labyrinth

- GX touch display

Bluetooth compatible, as well as remote control of van electronics

-4 Victron LiFePo4 Batteries

12v 100 amp hours each

Pre-assembled metal drawer glides = Moryde latching drawer slides

Blum under-mount tandem full extension drawer glides

Blum Soft-close concealed cabinet door hinges

Tensioned upper cabinets that stay closed and open with ease

Pressurized spigot in the rear along with gauge for water tanks

More pictures

https://drive.google.com/drive/folders/1RGr2dM5GHtm4898w50TDwOCCi3x7IapW

Contact me for more details, or if you've got a van/camper/off-grid design in your head that I can help come to life.

Email me at

gypsyvanz414@gmail.com

Also posted on this site, which offers financing through their website

https://thevancamper.com/post/6336/ram-promaster-3500-for-sale

Financing website for RVs and Boats

https://marinebk.com/borrow/personal-loans/boat-rv

Ebay posting

https://www.ebay.com/itm/364205089899?mkcid=16&mkevt=1&mkrid=711-127632-2357-0&ssspo=4we391NtRzG&sssrc=2349624&ssuid=4we391NtRzG&var=&widget_ver=artemis&media=COPY

[head-post]

Europe’s car industry crisis: Weak demand, job losses, electric shift

As European Commission President Ursula von der Leyen convenes a “strategic dialogue” with key automotive industry players, the sector faces a perfect storm of challenges, according to Euractiv.

From plummeting demand and job cuts to the rocky transition to electric vehicles (EVs), European carmakers face immense pressure.

Weak demand

The core issue plaguing Europe’s car industry is weak demand. In 2024, two million fewer cars were produced compared to pre-pandemic levels, as rising living costs and high interest rates make new cars unaffordable for many Europeans.

As early as last year, Renault CEO Luca de Meo warned of a possible decline in purchasing power.

The European middle class is losing purchasing power.

The decline in affordability is particularly acute for EVs, whose prices have risen despite falling battery costs. Compounding the problem is the “local for local” trend, where carmakers like German brands increasingly produce vehicles in their target markets, such as the US, rather than in Europe.

Job losses and factory closures

Fewer cars produced in Europe mean fewer jobs. In 2024 alone, 88,000 job cuts were announced, including Volkswagen’s plan to reduce its workforce by 35,000 by 2030. While VW aims to avoid layoffs by relying on retirements, the industry’s ageing workforce underscores a broader issue of overcapacity.

Meanwhile, critics like William Todts of Transport & Environment argue that record profits in recent years undermine claims of a crisis, attributing gains to delayed electrification investments and cost-cutting measures, including lower wages.

The shift to EVs exacerbates job losses, as electric vehicles require fewer assembly workers and render entire supply chains for internal combustion engine parts obsolete. Unions are calling for a moratorium on factory closures and forced redundancies to ensure negotiated solutions for affected workers.

Electric shift off-track

The transition to electric mobility remains a contentious issue. While there is consensus that EVs and fuel cells will dominate the future, sales figures fall far short of targets.

Carmakers blame weak consumer confidence, citing a lack of charging infrastructure and the reliance on purchase subsidies. In Germany, the abrupt end of EV incentives led to a sharp drop in demand.

German Chancellor Olaf Scholz has urged the EU to implement a bloc-wide subsidy scheme, whereas Transport & Environment criticises carmakers for focusing on premium EV models, driving up prices.

Carmakers argue they are already selling EVs at a loss and face looming fines for missing CO2 targets. The European Automobile Manufacturers’ Association (ACEA) is pushing for flexibility in enforcement, a stance supported by Germany, France, Italy, and Czechia. The European Commission’s recent Competitiveness Compass hints at potential compromises, such as averaging targets over several years.

Call for action

Trade unions sympathise with the industry’s struggles, noting the lack of demand for EVs undermines fleet renewal goals. Judith Kirton-Darling, general secretary of the European trade Union federation IndustriAll, stressed the urgency of EU measures to boost EV adoption but warned that current austerity policies contradict these efforts.

As Europe’s car industry navigates this crisis, the path forward hinges on balancing competitiveness, workforce protection, and the ambitious transition to electric mobility. The outcome of von der Leyen’s strategic dialogue could shape the sector’s future for decades to come.

Read more HERE