EV - the vital role of encoders in electric vehicle

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Electric vehicle - driving the EV revolution

Rapidly growing demand for electric vehicle (EV) manufacture is revolutionising the automotive sector. To meet supply chain demands, EV battery production needs to be ramped up dramatically. Encoders are essential to overcoming this challenge, and Renishaw has an extensive range of precision encoders, meticulously engineered for critical functions, ensuring unparalleled reliability and performance.

The vital role of encoders in EV production

A banner of various Renishaw position encoders, including optical encoders and magnetic encoders.jpg

EV battery cell production

The production of EV batteries demands cutting-edge manufacturing equipment capable of generating consistent, top-tier battery cells. Essential to this equipment are dependable encoders, which provide precise position feedback, speed and direction control throughout the manufacturing journey. This focus on precision improves yield rates and elevates overall quality.

Batteries from an electric vehicle

Stacking

As an integral part of EV battery production, stacking machines rely on encoders to achieve precise alignment for components, such as electrode placement and module alignment.

Absolute encoders come to the fore in high-speed contexts, particularly when deploying linear motor technology with multiple stacking heads. This integration optimises efficiency and amplifies yield rates.

The RESOLUTE™ true-absolute encoder is a high-speed, fine-resolution position measurement system. Position is acquired immediately on start-up, without requiring any motion, offering smooth velocity control and dependable positional stability.

Pocket stacking in lithium-ion battery cell production

Winding

As an alternative to stacking, winding comes into play in the production of cylindrical and prismatic cells. This process involves wrapping foils around a mandrel or centre pin.

High-precision motion systems often use direct-drive rotary (DDR) motors featuring integrated encoders, which offer increased stability, speed and responsiveness.

The RESOLUTE™ true-absolute encoder measures absolute position with fine resolutions down to 1 nm and high speeds up to 100 m/s, delivering exceptional metrology performance.

Production of cylindrical and prismatic for EV battery cells - Winding.jpg

Renishaw resolute - true absolute encoder measures absolute position with fine resolutions.jpg

The winding process in EV battery cell production involves rolling the anode, cathode, and separator together

Welding

High-speed welding machinery in EV battery production rely on precision encoders for flawless, burr-free welding. Absolute encoders, coupled with linear motor technology, ensure accuracy in small radius arc welding for high-quality batteries.

The LA12 true absolute magnetic encoder system is designed for motion control applications as a position and velocity control loop feedback element. The encoder readhead is sealed to IP67 providing reliable operation with resolutions up to 0.244 µm.

EV battery cell production - illustration of a high-speed welding machinery.jpg

Inspection

The motion systems used in component inspection, demand high levels of accuracy and performance. Inspection machines equipped with Renishaw’s precision encoder technologies, allow manufacturers to quickly identify defects and increase throughput.

The RESOLUTE™ true-absolute encoder provides absolute position measurement with low Sub-Divisional Error (SDE) of ±40 nm and ultra-low noise (jitter) of less than 10 nm RMS, resulting in smooth velocity control performance and dependable positional stability.

EV battery cell production - illustration of a component inspection machine with inspection sensor.jpg

EV battery cell production - production line.jpg

EV traction motor production

The backbone of electric vehicles lies within their traction motors, whether in the form of direct drive or geared motors. Position encoders are typically employed to precisely measure rotor positions and speeds in real-time. This enables pinpoint control over motor torque and speed via the motor controller, ensuring an efficient and reliable vehicle operation while safeguarding components from overheating or stall-inducing damage.

Electric vehicles require high accuracy, high resolution encoders for optimum performance. Ensuring the encoders are as lightweight and compact as possible yet still capable of withstanding demanding operational conditions will ensure energy efficiency. Seamless compatibility with the EV motor and control system are also vital.

The RM16 incremental and absolute encoder is a compact, sealed, high speed rotary magnetic encoder designed for use in space-constrained applications. With its super small 16 mm diameter body, the RM16 is an excellent chose for electric vehicles traction motor.

illustration of an electric vehicle’s traction motor.png

Cutaway view of an electric vehicle’s motor

What to consider when selecting encoder systems for EVs?

The table below outlines the key factors typically evaluated when choosing an encoder system for electric vehicle applications. These factors include encoder performance, environment conditions, installation requirements, and other relevant considerations.

Electric vehicles

Performance

✔ Resolution
✔ Rotary range
✔ Speed
✔ Controller input frequency

Environment

✔ Temperature
✔ Humidity
✔ Vibration
✔ Electromagnetic compatibility (EMC)
✔ IP rating

Installation

✔ Size
✔ Ride height tolerance
✔ Yaw / pitch / roll

Others

✔ Analogue / digital
✔ Interpolation clock frequency
✔ Alarm type
✔ Automotive certificate

Success stories: automotive

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Reliable operation, race after race

Salakazi Racing has equipped its dragster with an automatic three disc, four-stage clutch fitted with a digital controller. The pre-programmed controller engages the clutch when the rider snaps open the throttle - that's where the Renishaw RM22 encoders with their ability to monitor up to 30,000 rpm come into play.

We've located the magnetic actuator directly on the end of the shaft. The encoder body is on the other side, in the clutch housing. I honestly think that only a space rocket would be a tougher environment for the encoder.

Salakazi (Finland)

The RM22 is a compact, high-speed rotary magnetic encoder designed for use in harsh environments. The non-contact two part design removes the need for seals or bearings ensuring long-term reliability and simple installation.

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Motorsport - securing pole position

For customers in elite motorsport and the automotive sector, Dynisma's motion generator accurately simulates motion cues in minute detail to provide a totally immersive driving experience. The motion generator is also designed for vehicle dynamics testing and NVH (noise, vibration, and harshness) applications in automotive development.

Dynisma selected the LA11 absolute magnetic linear encoder from Renishaw associate company RLS, to enable precise position control of the belt-driven actuators that drive the a low-frequency platform responsible for large movements (excursions).

The LA11 was ideal because it minimised our space requirements by producing both absolute and incremental signals from one readhead and scale tape.

We have a very strong working relationship with Renishaw and RLS. We have also received excellent product selection help and technical support from both businesses.

Dynisma (UK)

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Electric vehicles

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For electric vehicles (EVs)

RESOLUTE™ true-absolute encoder

The true-absolute encoder with a high-speed fine-resolution position measurement system. Position is acquired immediately on start-up without requiring any motion, offering smooth velocity control and dependable positional stability. Available with linear and rotary scales with a variety of serial interfaces.

✔ High speed

✔ Excellent dirt immunity

✔ Low SDE

✔ Low jitter

More details

ATOM™ miniature optical encoder

The miniature optical incremental linear and rotary encoder system offers innovative design combining miniaturisation with leading-edge signal stability, dirt immunity and reliability.

✔ Miniature

✔ Advanced signal stability

✔ Dirt immunity

✔ Reliability

More details

QUANTiC™ incremental encoder

Integrates proven filtering optics and interpolation technology into a super-compact, analogue or digital incremental open optical encoder, with wide installation tolerances and built-in calibration functions.

✔ Wide installation tolerances

✔ Dirt immunity

✔ High performance

✔ Robust

More details

LA12 absolute magnetic encoder

Designed for motion control applications as a position and velocity control loop feedback element. LA12’s readhead is sealed to IP67 providing reliable operation with resolutions up to 0.244 µm and supports Mitsubishi, Yaskawa and Fanuc serial communication.

✔ True absolute system

✔ Robust design and great EMC compatibility

✔ Suitable for highly dynamic control loops

✔ Resistant to oils, coolants, and grease

More details

RM16 incremental and absolute encoder

A compact, sealed, miniature, high speed rotary magnetic encoder designed for use in space limited applications. The encoder body is just 16 mm in diameter in aluminium housing.

✔ Super small size

✔ Non-contact, frictionless design

✔ High speed

✔ RoHS compliant

More details

OnAxis™ encoder modules

Rotary magnetic encoder modules consist of a magnet and a separate sensor board. A wide range of package configurations makes them ideal for integration into original equipment manufacturer (OEM) systems.

✔ Simple installation

✔ Low maintenance

✔ High reliability

✔ Low cost for OEM integration

More details

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Electric vehicle - driving the EV revolution

Success stories: automotive

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Reliable operation, race after race

Motorsport - securing pole position

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