Change In The Mobility Industry

To keep pace with the dynamics of the industry, OEMs rely on reliable and competent suppliers. We need partners who can react quickly to changing needs - from product development to prototype construction to series production. Prof. Dr. Konrad Saur, Vice President - Innovation & Technology at Trelleborg Sealing Solutions, knows the complex requirements of e-mobility.

"The market is very fast-paced and is developing at high speed," the expert describes the current situation. “This poses a challenge for manufacturers (OEMs) and their suppliers because customers often have neither clearly defined standards nor established solutions. Accordingly, the required rate of innovation and the pressure to bring the right products to market quickly are extremely high.”

On virtual paths against the corona crisis

In view of the latest developments relating to the corona virus, events are being canceled or postponed in a row. The future can belong to digital platforms that can compensate for this development. With the "Industrial Generation Network", the Vogel Communications Group presents a solution for professionals in the industry. As a digital supplement, the platform enables extensive networking: the focus is on digital encounters and establishing contacts, as well as product presentation and thematic exchange. Tools such as making appointments and video conferences enable professionals to network, make appointments and do research close to the respective branch. The platform thus replaces the currently severely restricted face-to-face communication, especially at trade fairs.

How can the platform help me?

When developing high-performance seals for electromobility, Trelleborg combines an efficient R&D organization with modern digital processes in order to keep the time until the first functional prototypes are available as short as possible. The finite element analysis (FEA) and other simulation programs used in the design make it possible to develop in the virtual world, to identify problems early and to avoid them if necessary. In this way, tight schedules can be met.

What has worked well for other industries can often be transferred to electromobility. In this way, the company uses its existing test systems and facilities to quickly find solutions. Examples are the fire test laboratory for the aerospace industry in Northborough, Masachusetts (USA), and the rotary test benches for applications in Stuttgart, Turin and two others in the USA and Great Britain.

Make e-mobility more efficient

“The different electrically powered vehicle classes require very similar sealing solutions. In all of them, for example, the battery must be protected against environmental influences and vibrations. A special challenge is that the chemical composition of the battery fluid in a charged battery differs from that in a discharged one,”says Saur. And with regard to rotary seals, he adds: “In the case of electrically driven motor vehicles, the requirements placed on the seals arranged on the E-axis are generally higher than in internal combustion engines. This is mainly due to the significantly higher operating speeds of the electric motors and the associated significantly higher temperatures in the area of rotary seals. Depending on the tribological situation, such components must alsoget along completely without lubrication or be compatible with the possibly chemically aggressive lubricant."

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Less friction, more range

The Hi-Spin PDR RT and Hi-Spin HS40 rotary seals are specifically designed for applications in the E-axis. They are designed to work effectively at the high speeds required to operate an E-axis efficiently. The two seal variants combine the sealing requirements that exist at high rotational speeds with low friction values - even with low lubrication - and help to increase the range of a vehicle or aircraft with an electric drive.

Turcon MC1 and Turcon MC2 as materials are the first electrically conductive compounds based on polytetrafluoroethylene (PTFE) for use in spring and elastomer-preloaded seals. They enable properties such as insulation, electrical and thermal conductivity and electromagnetic shielding to be ensured. The materials meet the requirements for the production of seals for the battery of the electric motor.

For the battery, Trelleborg also develops and produces customer-specific sealing solutions for the cover. Since the battery is adapted to the shape of the vehicle, the battery housing and its seal must also be tailored and meet additional functional requirements. They not only protect the battery from splash water and moisture, they also offer protection against pressurized water, a prerequisite for all battery manufacturers to achieve protection class IP66.

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Components seem insignificant

Saur is convinced that Trelleborg Sealing Solutions makes a significant contribution to e-mobility: “In relation to the complex entire system of an electric vehicle, the components from Trelleborg seem rather insignificant. In truth, however, they are crucial for the further development of electric vehicles. Together with our customers, we have already developed future-oriented solutions for electric mobility. We will continue to listen to them very closely and cooperate closely with them. We are proud to be an important player in this booming future market. We will continue to help shape the development with our innovations and contribute to making electrically powered vehicles more and more efficient in the future, thereby increasing their power density and range.”