Logistics provider DHL Supply Chain and connected automotive services provider Cox Automotive are working together to deliver in-life EV battery services for UK manufacturers and fleets.
The new cooperation provides battery repair, remanufacturing logistics and storage services at DHL’s EV Centre of Excellence in Rugby. Designed to comply with the latest government regulations and meet current battery safety standards, the new facility has the capacity to handle thousands of EV batteries each year. DHL has invested over £800,000 in a Battery Energy Storage System to discharge EV batteries and recirculate energy back into the site and remanufacturing process.
“Handling, transporting and storing EV batteries is a complex process, presenting some unique challenges,” said Paul Stone, MD Manufacturing Logistics DHL Supply Chain. “We’ve been listening and working with the industry to create a more robust end-to-end solution for EV batteries that effectively and reliably addresses challenges for manufacturers and fleets. This cooperation represents a major step forward in creating a scalable circular economy for batteries in the UK.”
“With 35,000 square feet of dedicated battery repair space, we can deliver vital battery services to customers under one roof,” said Martin Forbes, President, Cox Automotive International. “This new facility provides our customers with a unique EV handling service as it complements our existing vehicle services location just 13 miles away in Bruntingthorpe.”
Dot Transportation added a lone Orange EV electric terminal truck to its fleet in 2018. Some six years later, the yard dog, as terminal trucks are affectionately called, is still going strong after accumulating 30,000 hours on the clock, and it now has several additional Orange EV yard dogs to keep it company.
“DTI has seen substantial operational and environmental benefits, reducing its carbon footprint while enhancing efficiency and reducing costs at its distribution centers,” the company said.
DTI’s own calculations show that the single truck eliminated the need for approximately 45,000 gallons (170,000 liters) of diesel fuel while reducing CO₂ emissions by more than 500 tons. It has also lowered the firm’s operating costs by reducing maintenance and repair costs and energy usage.
The company has strategically placed charging stations to ensure that the trucks can maintain high uptime and can operate continuously across multiple shifts without interruption. Management considers the electric fleet to be “more dependable” than its former diesel fleet, and it aligns with DTI’s efficiency and environmental objectives.
Orange EV’s president, Kurt Neutgens, was proud to point out that “DTI’s 30,000-hour truck is operating on its original battery pack,” adding that “all of the more than 1,300 trucks in Orange EV’s commercially deployed fleet” also continue to operate on their original battery packs.
Based in Riverside, Missouri, Orange EV has been producing Class 8 all-electric terminal trucks since 2012. The company has the most deployed all-electric terminal trucks in the United States of any manufacturer, according to a February 2022 study by Calstart, a nonprofit consortium focused on increasing clean transportation.
Terminal trucks, which are also referred to as terminal tractors—as well as by several more colorful names including yard goats, yard dogs, yard mules and, in the UK, terminal lorries—are semi-tractor vehicles designed to move semi-trailers within a warehouse facility, cargo yard or intermodal facility.
Mercedes-Benz has successfully developed a solid-state battery prototype, potentially revolutionizing EV range and performance. Engineers from Mercedes AMG High Performance Powertrains (HPP) and the Mercedes Benz Center of Competence for […]
An oft-cited concern about the transition to electric vehicles is the availability of high-speed Direct Current Fast Charging (DCFC) infrastructure to enable convenient travel beyond the single charge range of today’s vehicles. Many OEMs are considering a move to 800V architecture from the widely available 400V platforms of most mass market EVs.
While this can have benefits to both vehicle efficiency and charging speed, it comes with a problem: much of the installed high-power DCFC infrastructure in the US and Europe is limited to 400 Volt, necessitating additional, costly equipment for an 800V vehicle to properly interface. Eaton’s Battery Configuration Switch (BCS) addresses this challenge with an innovative solution integrated into the EV battery pack.
Designed for passenger and light-duty commercial vehicles, the BCS is a bi-stable device that efficiently transitions pack voltage between 400 and 800 volts to maximize charging speed on all publicly available infrastructure.
In its normal operating mode, the BCS connects two 400-volt sub-packs in series to achieve 800 volts. When a reduced voltage is needed, it reconfigures the battery into two parallel 400 Volt sub-packs, allowing the EV to charge efficiently on 400 Volt DC fast chargers. This reconfiguration capability eliminates the need for multiple contactors, busbars, and harnesses, reducing cost and complexity while enhancing charging performance.
The BCS also enhances safety by using an internal rotary switch to prevent short circuits from collisions, software bugs, or contactor malfunctions. It maintains a stable position without low voltage hold current, improving vehicle efficiency and ensuring functionality even if low voltage power is lost.
Join this webinar at next week’s Virtual Conference on EV Engineering, presented by Eaton to learn about how Eaton’s BCS represents a significant advancement in EV technology, offering a robust, efficient, and cost-effective solution for battery pack voltage reconfiguration, underscoring Eaton’s commitment to innovation and excellence in power management.
Other sessions at our next Virtual Conference include:
High-Voltage Protection In DC Fast Charging
Join this webinar, presented by TTI and Sensata, to gain knowledge about high-voltage DC protection, such as contactors, isolation monitoring modules and fast disconnects that can add innovation, expertise and scale to your projects.
HVDC systems demand robust protection mechanisms to ensure operational safety and reliability. This webinar explores critical components such as high-voltage contactors, which enable rapid and reliable disconnection using hermetically sealed arc chambers; isolation monitoring modules, which continuously assess insulation resistance to detect faults in EVs and charging systems; and fast disconnect devices like fuses and active fuses, which provide overcurrent and arc fault protection. Emphasis is placed on their design and operational principles in multiple applications.
Broadcast live on March 10-13, 2025, the conference content will span the EV engineering supply chain and ecosystem, including motor and power electronics design and manufacturing, cell development, battery systems, testing, powertrains, thermal management, circuit protection, wire and cable, EMI/EMC and more.
Battery pack maker Felten has announced the debut of its new mobile energy storage product, the Charge Qube.
The Charge Qube is a rapidly-deployable, modular mobile battery energy storage system (BESS) that repurposes second-life batteries and ISO containers.
“The Charge Qube delivers immediate energy solutions for fleet operators, public charging stations, construction sites and remote or temporary or semi-permanent power needs,” the company said.
The new Charge Qube provides sustainable energy thanks to its integrated solar and wind energy capabilities. The Charge Qube, which is made in the UK, is delivered in a 10-foot ISO container, and can act as a standalone power source or be integrated with other energy networks. It supports up to five satellite stalls with twin chargers and offers scalable energy storage varying from 150 kWh to 450 kWh per unit. An optional 20-foot container variant with a capacity of 900 kWh, is expected to be available in Q2 2025.
The Charge Qube has AC and DC charging capabilities, and is available in three variants. An energy storage-only option provides flexible, off-grid power. A second version offers Type 2 AC charging—two chargers on the Qube along with pairs of 7 kW chargers on up to five satellite stalls. It supports up to 12 EVs simultaneously at 7 kW per port. The CCS DC fast charging version features dual 240 kW chargers, and is suitable for high-speed public and commercial EV charging.
Join this webinar at our March Virtual Conference on EV Engineering, presented by ACL, as we dive into an innovative approach to building vehicle bucks with greater efficiency and enhanced functionality. Designed to streamline development and testing, this virtual test environment enables faster prototyping, improved validation processes, and greater adaptability for a wide range of applications.
Other sessions at our next Virtual Conference include:
Testing BMS Systems On Signal Level With Cell Controller Virtualization
Hardware-in-the-loop (HIL) systems, that test Battery Management Systems (BMS) with cell controllers as part of the ‘System under Test,’ typically require complex high-voltage (HV) configurations for simulating the battery pack.
By means of virtualization, the cell controller functionality is moved into the simulation, allowing the HIL to provide cell controller communication to the BMS. This means the functionality of the cell controller can be simulated, resulting in a less complex HIL setup with fewer HV components.
Join this session, presented by Space, to learn more about testing BMS systems on a signal level with cell controller virtualization.
Broadcast live on March 10-13, 2025, the conference content will span the EV engineering supply chain and ecosystem, including motor and power electronics design and manufacturing, cell development, battery systems, testing, powertrains, thermal management, circuit protection, wire and cable, EMI/EMC and more.
Volvo is set to launch its new fully electric ES90 model featuring 800-volt technology, marking a significant advancement in the company’s EV portfolio. The upcoming sedan will offer a driving […]
Repurposing EV batteries for stationary energy storage applications seems like an ideal situation: keep batteries out of landfills and reduce reliance on recycling and new raw materials. It is well documented that EV batteries at the end of their vehicle life still maintain sufficient capacity and state of health for use in lower power applications, such as grid-tied energy storage.
However, existing EV battery validation is not directly harmonized with the regulatory and certification requirements for stationary energy storage systems.
Join this webinar at our March Virtual Conference on EV Engineering, presented by Intertek, where we will discuss the highlights of the NRTL certification and global regulatory concerns with the repurposing of EV batteries, with a focus on compliance with ANSI/CAN/UL 1973 and 9540, as well as key processing considerations according to UL 1974.
Other sessions at our next Virtual Conference include:
Master The Development Of DC Charging Stations: EVSE Challenges Unveiled
This webinar presentd by comenso electronics will reveal the complexities of developing DC charging stations, addressing critical issues such as evolving regulations, interoperability challenges, rigorous testing requirements, and the intricate landscape of charging standards.
Our expert panel will share practical insights and strategies to overcome these obstacles, ensuring your solutions not only comply with current standards but are also future-proof. Ideal for engineers, product managers, and industry leaders, this session will equip you with actionable takeaways to navigate the ever-evolving EV charging ecosystem.
Join this session, where we dive into real-world lessons learned from the field.
Broadcast live on March 10-13, 2025, the conference content will span the EV engineering supply chain and ecosystem, including motor and power electronics design and manufacturing, cell development, battery systems, testing, powertrains, thermal management, circuit protection, wire and cable, EMI/EMC and more.
As the battery industry is projected to surpass $300 billion by 2030, driven by the rise of electric vehicles and renewable energy storage, manufacturers face the dual challenge of rapid innovation and stringent quality requirements. Traditional testing methods often fall short in detecting internal defects or optimizing complex designs. CT scanning addresses these challenges by providing non-destructive, detailed internal visualizations of battery cells, enabling engineers to find misalignments, folds, tears, and other internal defects without disassembling the cell. This capability accelerates development, enhances reliability, and supports faster innovation cycles.
In research and development, CT scanning is invaluable for accelerating material development by visualizing the distribution of materials within a battery cell, allowing for the early detection of flaws like internal cracking or voids. It also aids in identifying defects in new chemistries and form factors, such as delamination in solid-state batteries or dendrite formation in lithium-metal systems, which are critical for ensuring performance and safety before large-scale production. By integrating CT scanning into both R&D and production processes, battery manufacturers can enhance quality control, reduce waste, and bring innovative products to market more efficiently. Download this whitepaper to learn more.
New research carried out by Imperial College London indicates that recycled EV battery materials produced by UK-based Altilium can match the performance of mined materials.
Imperial’s analysis of Altilium’s commercial-grade recycled cathode active materials (CAM), which it began producing late last year, confirmed improvements in purity, morphology and electrochemical performance compared to commercially available materials, according to the company. This can potentially deliver improvements in battery performance, including longer battery life, faster charging times and lower costs.
Under the research program, Imperial carried out extensive electrochemical testing of coin cells and pouch cells manufactured with recycled CAM produced at Altilium’s ACT1 facility in Devon. The results demonstrated high rate and cycle performance compared to commercially available CAM used in high-nickel nickel manganese cobalt (NMC) 811 batteries. Altilium’s cycle cell capacity exceeded 150 mAh.g⁻¹, outperforming typical ranges for mined materials.
The analysis also showed advancements in particle size and distribution, contributing to improved stability and cycling behavior. Minor changes observed during testing affirmed the recycled CAM’s chemical and physical robustness. Consistent particle sizes aid in the production of CAM with better electrochemical properties.
Altilium’s EcoCathode process can recover over 95% of critical metals, including lithium, from end-of-life EV batteries. Unlike mined ores, which vary in quality and require extensive refining to remove impurities, recycled materials are derived from standardized, manufactured batteries, reducing impurities and variability in metal composition. Recycled CAM precursors can also retain favorable crystal structures and grain morphology, which can be leveraged during re-synthesis for high-performance materials.
“Altilium is working with the UK Battery Industrialisation Centre (UKBIC) to produce battery cells using its recycled CAM, for validation with a leading automotive OEM,” the company said.
