Study Claims EV Adoption Targets Are Unachievable

NEWS

ZURICH—According to a study commissioned by ABB Robotics, more than half (59 percent) of respondents believe the shift to pure electric vehicle production is not achievable within current legislative timelines.

Challenges include adapting to a new battery supply chain, concerns over high levels of capital investment required, shortages of raw materials, suitable infrastructure and lack of grid capacity.

Although 28 percent of respondents say the deadlines are achievable, 18 percent believe the present targets will never be met. Only 11 percent think all regional targets for EV adoption by 2040 are realistic.

“The automotive industry is acutely aware of the stresses and strains involved in meeting the proposed regional timetables for reaching full EV production,” says Joerg Reger, managing director of ABB Robotics Automotive Business Line.

“Automation is key to making production more resilient, efficient and faster to meet these targets, which is why we’re seeing high demand for robots that specialize in EV power train assembly,” notes Reger. “These [machines] radically reduce build times, improve flexibility, further simplify the production process and ultimately drive down production costs.”

The survey also highlighted the challenges involved in adapting to a new battery supply chain, cited as a key barrier by 19 percent of respondents, while 16 percent have concerns over the high levels of capital investment required. Shortages of raw materials, suitable infrastructure, and lack of grid capacity were also high on the list of issues yet to be resolved.

Elsewhere, the lack of charging infrastructure was quoted as the single biggest constraint to EV adoption by more than a quarter (26 percent) of those surveyed, while 17 percent highlighted high vehicle prices as the principal barrier to EV growth.

“The survey confirms…that manufacturing is under strain and disrupted supply chains are under considerable stress,” says Daniel Harrison, an analyst at Automotive Manufacturing Solutions, which cosponsored the study. “This is likely to be the ‘new never normal,’ which poses considerable challenges to how quickly the industry can transition to electrification and also wider manufacturing sustainability targets, especially during a period of great economic uncertainty.”

Volkswagen to Produce Low-Cost EV

WOLFSBURG, Germany—Most electric vehicles produced so far have been high-end models that cost more than $50,000. However, for EVs to really take off and appeal to consumers, the auto industry needs to mass-produce cars that cost half that much. When that happens, it will be similar to the watershed moment when Ford Motor Co. launched the Model T back in 1908.

Volkswagen AG hopes history repeats itself with its just-announced ID.2all. The compact hatchback will cost approximately $27,000 when it debuts in 2025. It will be similar in size to a VW Golf, but priced like a Polo, VW’s entry-level car sold in Europe.

“The ID. 2all will be the first MEB (modular electric drive) vehicle with front-wheel drive,” says Kai Grünitz, member of the VW brand board of management responsible for development. “We are exploiting the great flexibility offered by our MEB platform and will set new standards in terms of technology and everyday usability with the new vehicle.”

Nissan Unveils New EV Power Train Initiative

YOKOHAMA, Japan—Nissan Motor Corp. has unveiled a new approach to electrified power train development. Its “X-in-1” initiative features shared, modular components that will reduce manufacturing costs by 30 percent.

Nissan engineers have developed a 3-in-1 power train prototype that modularizes the motor, inverter and reducer. A 5-in-1 prototype, which additionally modularizes the generator and increaser, is also under development for use in future EVs. To cut costs and improve efficiency, all of the components will be produced on the same assembly line.

“We make the most of our expertise and know-how from our more-than-a-decade-long development and production of electrified technologies,” says Toshihiro Hirai, senior vice president of power train and EV engineering development at Nissan. “Through our innovations in electrified power train development, we’ll continue to create new value for customers and deliver 100 percent motor-driven vehicles as widely as possible.”

Under its long-term vision, Nissan Ambition 2030, the company plans to bolster its vehicle lineup with 27 new electrified models, including 19 EVs, by the end of this decade.

Foxconn to Produce EV Batteries in Ohio and Wisconsin

MOUNT PLEASANT, WI—Foxconn Technology Group plans to produce batteries at its factories here and in Lordstown, OH. The contract manufacturer is currently making electric pickup trucks and tractors at the later facility, which was previously owned by General Motors.

“We will develop new energy industry in Wisconsin, including battery cells and battery packs,” says Young Liu, chairman of Foxconn. “Ohio will mainly be EV battery packs, while Wisconsin will mainly have new energy, energy storage systems and battery cells.”

Foxconn’s controversial factory in Wisconsin has a long history of broken promises and unfulfilled plans. In 2017, the company claimed that it would invest $10 billion in a massive complex of factories on farmland near Racine that would cover 20 million square feet and generate 13,000 jobs. The factory was supposed to mass-produce flat-panel display screens for computers, televisions and other electronic devices.

After the much-touted announcement attended by local, state and federal government officials, millions of dollars were invested in roads and infrastructure improvement projects, but only two buildings were ever built. Today, Foxconn uses the site to produce computer servers and motherboards, with fewer than 1,000 employees.

BMW Invests in Electric Motor Start-Up

MOUNTAIN VIEW, CA—BMW AG is investing $16 million in DeepDrive, a startup manufacturer that has developed a dual-rotor motor that can extend the range of electric vehicles.

DeepDrive’s radial flux motor includes power electronics and can be installed in any vehicle as a central drive or as an in-wheel drive. The patented device achieves high torque density, is cost-efficient to manufacture and requires fewer natural resources than alternatives.

"We believe our technology will revolutionize vehicle electrification,” says Felix Pörnbacher, CEO of DeepDrive. “With our dual-rotor technology, we are significantly more cost-effective and efficient on the road, shaping tomorrow's electromobility. The demand for our development shows that we are on the right track.”

The company is working with many top automakers and is on track to bring its technology to production by 2026.

"With its patented and unique e-motor architecture, DeepDrive could set new standards for e-mobility,” explains Marcus Behrendt, managing director of BMW i Ventures. “The highly efficient e-motors offer major advantages in terms of weight, cost and space.

“They enable the next generation of efficient and resource-saving electric vehicles,” claims Behrendt. “DeepDrive's e-motor technology is designed for easy and cost-effective mass production. We are pleased that our involvement can help this new technology achieve a breakthrough."

Honda Outlines Plan to Transition U.S. Plants from ICE to EV

MARYSVILLE, OH—Honda Motor Co.’s flagship factory here will be the automaker’s first U.S. facility to transition to making electric vehicles.

The Marysville Auto Plant (MAP) will begin preparing for EV production early next year by consolidating its two production lines currently making vehicles powered by internal combustion engines and hybrid-electric vehicle systems.

Consolidating production to one line will enable MAP to begin building the infrastructure necessary for EV production. Starting later this year, assemblers will begin a training programs designed to prepare them for the skills required for EV production.

Each Honda auto production facility in North America will have a critical role to play in the company’s electrification strategy. For instance, its transmission plant in Tallapoosa, GA, will partner with a Honda supplier to install a new line to build e-axles. The supplier will install, own and operate the new assembly line in space currently occupied by a transmission production line that is not in operation.

Hyundai Develops Robot for EV Charging

SEOUL—Engineers at Hyundai Motor Group have developed an automatic charging robot (ACR) for electric vehicles. The one-armed device can plug a cable into an EV’s charging port and remove it after charging.

Once a vehicle is stationary, the ACR communicates with the vehicle to open the charging port, calculating the exact location and angle through a camera. The robot then picks up the charger and fastens it to the vehicle’s charging port. Once charging is complete, the device removes the charger and closes the cover of the vehicle’s charging port.

“The ACR will help to make EV-charging easier and more convenient, especially in dark environments,” says Dong Jin Hyun, head of Hyundai’s robotics laboratory. “It will also improve accessibility, particularly for people with mobility barriers, as charging cables become thicker and heavier to enable high-speed charging. We will continue developing the ACR for increased safety and more convenience, so that all EV customers can soon benefit from using it at charging stations.”

The robot is dustproof and waterproof, with an IP65 environmental rating. A safety pole features a built-in laser sensor that enables the robot to safely detect stationary and moving obstacles.