BMW Pushing Hard For Solid-State Battery Tech; Plans Demo By 2025

April 21, 2021 by Lewin Day 26 Comments

Plenty of development is ongoing in the world of lithium batteries for use in electric vehicles. Automakers are scrapping for every little percentage gain to add a few miles of range over their competitors, with efforts to reduce charging times just as frantic as well.

Of course, the real win would be to succeed in bringing a bigger, game-changing battery to market. Solid state batteries fit the bill, potentially offering far greater performance than their traditional lithium counterparts. BMW think there’s merit in the technology, and have announced they intend to show off a solid-state battery vehicle by 2025.

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A Look At The Most Aerodynamic Cars Ever Built

April 20, 2021 by Lewin Day 77 Comments

Whether gasoline, diesel, or electric, automakers work hard to wring every last drop of mileage out of their vehicles. Much of this effort goes towards optimising aerodynamics. The reduction of drag is a major focus for engineers working on the latest high-efficiency models, and has spawned a multitude of innovative designs over the years. We’ll take a look at why reducing drag is so important, and at some of the unique vehicles that have been spawned from these streamlining efforts.

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Magna Announces Simple Drive Solution For Electric Pickup Trucks

April 14, 2021 by Lewin Day 68 Comments

Thus far, the majority of electric cars on sale have been aimed at commuters, fitting into the sedan and SUV segments of the marketplace. Going forward, there’s a very real need for electrification to touch the whole spectrum of automobiles, and that includes work vehicles like pickup trucks. A company called Magna have recently thrown their hat into the ring in just this space, developing a simple drivetrain that can be readily installed in pickup trucks without major modifications. Continue reading “Magna Announces Simple Drive Solution For Electric Pickup Trucks” →

Mercedes Split Turbo Was A Game Changer In Formula 1

April 6, 2021 by Lewin Day 40 Comments

In 2014, Formula 1 switched away from V8 engines, electing instead to mandate all teams race with turbocharged V6 engines of 1.6 litres displacement, fitted with advanced energy recovery systems. The aim was to return Formula 1 to having some vague notion of relevance to modern road car technologies, with a strong focus on efficiency. This was achieved by mandating maximum fuel consumption for races, as well as placing a heavy emphasis on hybrid technology.

The Mercedes W05 Hybrid was the first of 7 championship-winning F1 cars from the British-based, German-funded team. It quickly showed the value of the team’s split-turbo technology.

Since then, Mercedes have dominated the field in what is now known as the turbo-hybrid era. The German team has taken home every drivers and constructors championship since, often taking home the crown well before the season is over. Much has been made of the team’s engine as a key part of this dominance, widely considered to be more powerful and efficient than the competition at all but a few select races in the last seven years, and much of the credit goes to the company’s innovative split-turbo system. Today, we’ll explore why the innovation was such a game changer in Formula 1.

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Ford And HP Teamed Up To Drive Down Plastic Waste

April 3, 2021 by Kristina Panos 25 Comments

This mass manufacturer movement towards electric cars is one thing, but what about sustainability on the plastic part production line? Ford and HP have teamed up to turn used 3D printed parts and powders into pellets that will be fodder for injection-molded parts — specifically the fuel-line clips for Super Duty F250 trucks.

According to Ford’s press release, their goal is to reach 100% sustainable materials in all their vehicles, not just the diesel-drinking Super Duty. Their research team found ten other Fords whose existing fuel-line clips could instead be made sustainably, and the company plans to implement the recycled plastic clips on all future models.

There are all sorts of positives at play here: the recycled clips cost 10% less to make and end up weighing 7% less than traditionally-made clips, all the while managing to be more chemical and moisture resistant.

And so much plastic will be kept out of landfills, especially once this idea takes off and more manufacturers get involved with HP or form other partnerships. One of the sources of Ford’s plastic is Smile Direct Club, which has 60 printers cranking out over 40,000 dental aligners every day.

There’s more than one way to combine 3D printing and sustainability. Did someone say fungal sound absorbers?

[Images via Ford]

Classic Triumph Gets A Modern Digital Dash

March 31, 2021 by Lewin Day 46 Comments

Analog gauges gave way to all manner of fancy electroluminescent and LED gauges in the ’80s, but the trend didn’t last long. It’s only in the last decade or so that LCD digital gauges have really started to take off in premium cars. [Josh] is putting a modern engine and drivetrain into his classic Triumph GT6, and realised that he’d have to scrap the classic mechanical gauge setup. After not falling in love with anything off the shelf, he decided to whip up his own solution from scratch.

The heart of the build is a Raspberry Pi 4, which interfaces with the car’s modern aftermarket ECU via CANBUS thanks to the PiCAN3 add-on board. Analog sensors, such as those for oil pressure and coolant temperature, are interfaced with a Teensy 4.0 microcontroller which has the analog to digital converters necessary to do the job. Display is via a 12.3″ super-wide LCD sourced off Aliexpress, with the graphics generated by custom PixiJS code running in Chromium under X.

The result is comparable with digital displays in many other modern automobiles, speaking to [Josh]’s abilities not just as a programmer but a graphic designer, too. As a bonus, if he gets sick of the design, it’s trivial to change the graphics without having to dig into the car’s actual hardware.

Gauge upgrades are common on restomod projects; another route taken is to convert classical mechanical gauges to electronic drive. If you’re cooking up your own sweet set of gauges in the garage, be sure to drop us a line! Video after the break.

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The Difference Between 4WD And AWD

March 31, 2021 by Lewin Day 102 Comments

Car manufacturers will often tout a vehicle’s features to appeal to the market, and this often leads to advertisements featuring a cacophony of acronyms and buzzwords to dazzle and confuse the prospective buyer. This can be particularly obvious when looking at drivelines. The terms four-wheel drive, all-wheel drive, and full-time and part-time are bandied about, but what do they actually mean? Are they all the same, meaning all wheels are driven or is there more to it? Let’s dive into the technology and find out.

Part-Time 4WD

Part-time four-wheel drive is the simplest system, most commonly found on older off-road vehicles like Jeeps, Land Cruisers and Land Rovers up to the early 1990s, as well as pickup trucks and other heavy duty applications. In these vehicles, the engine sends its power to a transfer case, which sends an equal amount of torque to the front and rear differentials, and essentially ties their input shafts together. This is good for slippery off-road situations, as some torque is provided to both axles at all times. However, this system has the drawback that it can’t be driven in four-wheel drive mode at all times. With the front and rear differentials rotating together, any difference in rotational speed between the front and rear wheels — such as from turning a corner or uneven tyre wear — would cause a problem. The drive shaft going to one differential would want to turn further than the other, a problem known as wind-up.

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