New Electronics - Solving EV complexity with customised magnetic components

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Electric vehicles (EVs) have become a mainstay of the automotive market. Research from the International Energy Agency suggests global EV sales will reach 17 million by the end of 2024, accounting for more than one in five cars sold worldwide.

However, as these cutting-edge machines grow in popularity, they become increasingly complex, which presents manufacturers and engineers with a challenge - how do you maximise performance while optimising costs?

Could customised magnetic components offer a solution? Here, we discuss why the demand for EVs and charging points is so high and the benefits of manufacturing custom parts to reduce costs without compromising performance.

An Electrifying Rise

The automotive industry has experienced a seismic shift in recent years. The move towards electrification has been driven by the pressing need for sustainable transportation solutions and the global pursuit of Net Zero. Governments worldwide have committed to reducing carbon emissions, with EVs offering a cleaner, more efficient, technologically advanced driving experience.

For example, the European Union has passed a law that requires manufacturers to achieve a 100% reduction in CO2 emissions from new cars sold in the EU by 2035. The U.S. government has committed to a similar timescale. It plans to end the purchase of gas-powered vehicles and launched a plan to make half of all new U.S. vehicles electric by 2030.

Previous concerns such as range anxiety, battery performance and charging convenience have eased, and motorists seem committed to the electric revolution. With that, the quality of parts has improved too. The high magnetic strength of rare-earth magnets enables the use of smaller motors and generators, which reduces weight and improves range and efficiency.

Improvements in manufacturing processes have also streamlined assembly lines and reduced labour costs, which means EV production is more cost-competitive with traditional car manufacturing. This is aided by dedicated EV manufacturing plants and the expansion of existing facilities to allow car companies to scale up production.

Furthermore, electric car charging points have significantly improved. This is partially thanks to the integration of advanced magnetic components, which have increased battery life and efficiency. These components are crucial to managing power flow, regulating voltage levels and filtering electromagnetic interference. In addition, magnetic sensors are used to detect issues such as preventing hazardous situations during charging or detecting current leakages.

The Standard Versus Custom Debate

Every car manufacturer pursues elite performance but at the best price possible. Believe it or not, EVs consist of fewer parts than petrol-powered cars with an average of 15,000 parts, whereas their petrol counterparts average almost 30,000.

Sitting at the core of these vehicles and their charging systems are magnetic components. Motors, transformers and conductors work harmoniously to draw energy from the vehicle's batteries to ensure the smooth operation of the vehicle’s powertrain and electrical systems. For example, rare-earth magnets like neodymium are core components in the electric motors that power EVs. These powerful magnets interact with the motor’s coils to generate the rotational force that drives the wheels.

The key benefit of customised magnetic components is the ability to precisely tailor the design to the unique needs of electric cars and their charging units. For example, manufacturers can optimise parts to improve performance, efficiency and battery life. Magnets for motors, chargers and generators can be designed to fit optimal shapes, sizes and arrangements to minimise energy losses.

Yet many manufacturers are still tempted by standard off-the-shelf magnetic components, which they believe to be more cost-effective. In reality, these generic solutions often fail to meet the specific demands of EVs to deliver high-performance, energy-efficient and compact designs.

There may also be the misconception that customisation means extra expense. However, designing magnets for specific motor requirements can minimise the use of rare earth materials while still meeting performance targets, therefore reducing manufacturing costs. Increased automation across production lines also enables the mass manufacturing of customised magnetic assemblies, meaning complex parts can be made efficiently and cost-effectively.

Customised Magnetics - The Future of EVs

As we move forward, customised magnetic components offer significant advantages over off-the-shelf equivalents to EV manufacturers. By precisely tailoring the design and materials of components like motors, generators and charge units, automotive companies can optimise performance, efficiency and cost-effectiveness.

Transitioning to electrification offers a huge opportunity for the automotive sector to contribute to sustainability goals and change how cars are designed, built and charged. Customisation will be central to enabling car makers to push the boundaries of what these vehicles and components are capable of.

Author details: Declan Grady, Technical Manager at Talema Group