France Hits Record: 20% Of Market Buys Electric Cars

Canada EV Manufacturing Strategy catalyzes electric vehicles growth via batteries, mining, and supply chain localization, with Unifor deals, Ford and FCA retooling, and government incentives safeguarding jobs and competitiveness across the auto industry.

Key Points

A coordinated plan to scale EV assembly, batteries, and mining supply chains in Canada via union deals and incentives.

✅ Government-backed Ford and FCA retooling for EV models.

✅ Battery cell, module, and pack production localizes value.

✅ Mining-to-mobility links metals to the EV supply chain.

As of a month ago Canada was just a speck on the global EV manufacturing map. We couldn’t honestly claim to be in the global race to electrify the automotive sector, even as EV shortages and wait times signalled surging demand.

An analysis published earlier this year by the International Council on Clean Transportation and Pembina Institute found that while Canada ranked 12th globally in vehicle production, EV production was a miniscule 0.4 per cent of that total and well off the average of 2.3 per cent amongst auto producing nations.

As the report’s co-author Ben Sharpe noted, “Canada is a huge auto producer. But nobody is really shining a light on the fact that if Canada’s doesn’t quickly ramp up its EV production, the steady decline we’ve seen in auto manufacturing over the past 20 years is going to accelerate.”

National strategy
While the report received relatively scant attention outside industry circles, its thesis was not lost on the leadership of Unifor, the union representing Canadian autoworkers.

In an August op-ed, Unifor national president Jerry Dias laid out the table stakes: “Global automakers are pouring hundreds of billions of dollars into electric vehicle investments, but no major programs are landing in Canada. Without a comprehensive national auto strategy, and active government engagement, the future is dim … securing our industry’s future requires a much bigger made-in-Canada style effort. An effort that government must lead.”

And then he got busy at the negotiating table.

The result? All of a sudden Canada is (or rather, will be) on the EV assembly map, just as the market hits an EV inflection point globally on adoption trends.

Late last month, contract negotiations between Unifor and Ford produced the Ford Oakville deal that will see $2 billion — including $590 million from the federal and Ontario governments ($295 million each) — invested towards production of five EV models in Oakville, Ont.

Three weeks later, Unifor reached a similar agreement with Fiat Chrysler Automobiles on a $1.5-billion investment, including retooling, to accommodate production of both a plug-in hybrid and battery electric vehicle (including at least one additional model). 

Workforce implications
The primary motivation for Unifor in pushing for EVs in contract negotiations is, at minimum, preserving jobs — if not creating them. Unifor estimates that retooling the Ford plant in Oakville will save 3,000 of the 3,400 jobs there, contributing to Ontario's EV jobs boom as the transition accelerates. However, as VW CEO Herbert Diess has noted, “The reality is that building an electric car involves some 30 per cent less effort than one powered by an internal combustion engine.”

So, when it comes to the relationship between jobs and EVs, at first glance it might not seem to be a great news story. What exactly are the workforce implications?

To answer this question, and aid automakers and their suppliers in navigating the transition to EV production, the Boston Consulting Group (BCG) has done a study on the evolution of labour requirements along the automotive value chain. And the results, it turns out, are both illuminating and encouraging — so long as you look across the full value chain.

Common wisdom “inaccurate”
The study provides an in-depth unpacking of the similarities and differences between manufacturing an internal combustion engine (ICE) vehicle versus a battery EV (BEV), and in doing so it arrives at a surprising conclusion: “The common wisdom that BEVs are less labor intensive in assembly stages than traditional vehicles is inaccurate.” 

BCG’s analysis modeled how many labour hours were required to build an ICE vehicle versus a BEV, including the distribution of labour value across the automotive value chain.

While ICE vehicles require more labour associated with components, engine, motor and transmission assembly and installation, BEVs require the addition of battery manufacturing (cell production and module and battery pack assembly) and an increase in assembly-related labour. Meanwhile, labour requirements for press, body and paint shops don’t differ at all. Put that all together and labour requirements for BEVs are comparable to those of ICE vehicles when viewed across the full value chain.

Value chain shifting to parts suppliers
However, as BCG notes, this similarity not only masks, but even magnifies, a significant change that was already underway in the distribution of labour value across the value chain — an accelerating shift to parts suppliers.

This trend is a key reason why the Canadian Automotive Parts Manufacturers’ Association launched Project Arrow earlier this year, and just unveiled the winner of the EV concept design that will ultimately become a full-build, 100 per cent Canadian-equipped zero-emission concept vehicle. The project is a showcase for Canadian automotive SMEs.

The bulk of the value shift is into battery cell manufacturing, which is dominated by Asian players. In light of this, both the EU and UK are working hard to devise strategies to secure battery cell manufacturing, including projects like a Niagara Region battery plant that signal momentum, and hence capture this value domestically. Canada must now do the same — and in the process, capitalize on the unique opportunity we have buried underground: the metals and minerals needed for batteries.

The federal government is well aware of this opportunity, which Minister of Industry, Science and Economic Development Navdeep Bains has coined “mines to mobility.” But we’re playing catch up, and the window to effectively position to capture this opportunity will close quickly.

Cooperation and coordination needed
As Unifor’s Dias noted in an interview with Electric Autonomy after the FCA deal, the scale of the opportunity extends beyond the assembly plants in Oakville and Windsor: “This is about putting workers back in our steel plants. This is about making batteries. This is about saying to aluminum workers in Quebec and B.C. … to lithium workers in Quebec … cobalt workers in Northern Ontario, you’re going to be a part of the solution…It is a transformative time. … We’re on the cusp of leading globally for where this incredible industry is going.”

With their role in securing Ford’s EV production commitment, the federal and Ontario governments made clear that they understand the potential that EVs offer Canada, including how to capitalize on the U.S. auto sector's pivot as supply chains evolve, and their role in capitalizing on this opportunity.

But to ultimately succeed will require more than an open chequebook, it will take a coordinated industrial strategy that spans the full automotive value chain and extends beyond it into batteries and even mining, alongside Canada-U.S. collaboration to align supply chains. This will require effective cooperation and coordination between governments and across several industrial sectors and their associations.

Together they are Team Canada’s pit crew in the global EV race. How we fare will depend on how efficiently and effectively that crew works together. 

Related News

• Electricity Forum News

• EV Infrastructure News

IEA World Energy Outlook 2020 highlights solar power as the cheapest electricity, projects faster renewables growth, models net-zero pathways, assesses COVID-19 impacts, oil and gas demand, and policy scenarios including STEPS, SDS, and NZE2050.

Key Points

A flagship IEA report analyzing energy trends, COVID-19 impacts, renewables growth, and pathways to net-zero in 2050.

✅ Solar now the cheapest electricity in most major markets

✅ Scenarios: STEPS, SDS, NZE2050, plus delayed recovery case

✅ Oil and gas demand uncertain; CO2 peak needs stronger policy

The world’s best solar power schemes now offer the “cheapest…electricity in history” with the technology cheaper than coal and gas in most major countries.

That is according to the International Energy Agency’s World Energy Outlook 2020. The 464-page outlook, published today by the IEA, also outlines the “extraordinarily turbulent” impact of coronavirus and the “highly uncertain” future of global energy use and progress in the global energy transition over the next two decades.

Reflecting this uncertainty, this year’s version of the highly influential annual outlook offers four “pathways” to 2040, all of which see a major rise in renewables across markets. The IEA’s main scenario has 43% more solar output by 2040 than it expected in 2018, partly due to detailed new analysis showing that solar power is 20-50% cheaper than thought.

Despite a more rapid rise for renewables and a “structural” decline for coal, the IEA says it is too soon to declare a peak in global oil use, unless there is stronger climate action. Similarly, it says demand for gas could rise 30% by 2040, unless the policy response to global warming steps up.

This means that, while global CO2 emissions have effectively peaked flatlining in 2019 according to the IEA, they are “far from the immediate peak and decline” needed to stabilise the climate. The IEA says achieving net-zero emissions will require “unprecedented” efforts from every part of the global economy, not just the power sector.

For the first time, the IEA includes detailed modeling of a 1.5C pathway that reaches global net-zero CO2 emissions by 2050. It says individual behaviour change, such as working from home “three days a week”, would play an “essential” role in reaching this new “net-zero emissions by 2050 case” (NZE2050).

Future scenarios
The IEA’s annual World Energy Outlook (WEO) arrives every autumn and contains some of the most detailed and heavily scrutinised analysis of the global energy system. Over hundreds of densely packed pages, it draws on thousands of datapoints and the IEA’s World Energy Model.

The outlook includes several different scenarios, to reflect uncertainty over the many decisions that will affect the future path of the global economy, as well as the route taken out of the coronavirus crisis during the “critical” next decade. The WEO also aims to inform policymakers by showing how their plans would need to change if they want to shift onto a more sustainable path, including creating the right clean electricity investment incentives to accelerate progress.

This year it omits the “current policies scenario” (CPS), which usually “provides a baseline…by outlining a future in which no new policies are added to those already in place”. This is because “[i]t is difficult to imagine this ‘business as-usual’ approach prevailing in today’s circumstances”.

Those circumstances are the unprecedented fallout from the coronavirus pandemic, which remains highly uncertain as to its depth and duration. The crisis is expected to cause a dramatic decline in global energy demand in 2020, with oil demand also dropping sharply as fossil fuels took the biggest hit.

The main WEO pathway is again the “stated policies scenario” (STEPS, formerly NPS). This shows the impact of government pledges to go beyond the current policy baseline. Crucially, however, the IEA makes its own assessment of whether governments are credibly following through on their targets.

The report explains:

“The STEPS is designed to take a detailed and dispassionate look at the policies that are either in place or announced in different parts of the energy sector. It takes into account long-term energy and climate targets only to the extent that they are backed up by specific policies and measures. In doing so, it holds up a mirror to the plans of today’s policy makers and illustrates their consequences, without second-guessing how these plans might change in future.”

The outlook then shows how plans would need to change to plot a more sustainable path, highlighting efforts to replace fossil fuels with electricity in time to meet climate goals. It says its “sustainable development scenario” (SDS) is “fully aligned” with the Paris target of holding warming “well-below 2C…and pursuing efforts to limit [it] to 1.5C”. (This interpretation is disputed.)

The SDS sees CO2 emissions reach net-zero by 2070 and gives a 50% chance of holding warming to 1.65C, with the potential to stay below 1.5C if negative emissions are used at scale.

The IEA has not previously set out a detailed pathway to staying below 1.5C with 50% probability, with last year’s outlook only offering background analysis and some broad paragraphs of narrative.

For the first time this year, the WEO has “detailed modelling” of a “net-zero emissions by 2050 case” (NZE2050). This shows what would need to happen for CO2 emissions to fall to 45% below 2010 levels by 2030 on the way to net-zero by 2050, with a 50% chance of meeting the 1.5C limit, with countries such as Canada's net-zero electricity needs in focus to get there.

The final pathway in this year’s outlook is a “delayed recovery scenario” (DRS), which shows what might happen if the coronavirus pandemic lingers and the global economy takes longer to recover, with knock-on reductions in the growth of GDP and energy demand.

Related News

• Electricity Forum News

• Climate Change News

Electric Vehicles deliver longer range, faster charging, and broader price options, with incentives and lease deals reducing costs; evaluate performance, home charging, road trip needs, and vehicle types like SUVs, pickups, and vans.

Key Points

Electric vehicles are battery-powered cars that cut costs, boost performance, and charge at home or at fast stations.

✅ Longer range and faster charging reduce range anxiety

✅ Lower operating costs vs gas: fuel, maintenance, incentives

✅ Home Level 2 charging recommended; plan for road trips

Electric cars now drive farther, charge faster and come in nearly every price range. But when GMC began promoting its Hummer EV pickup truck to be released this year, it became even clearer that electric cars are primed to go mainstream for many buyers.

Once the domain of environmentalists, then early adopters, electric vehicles may soon have even truck bros kicking the gasoline habit, though sales are still behind gas cars in many markets.

With many models now available or coming soon — and arriving ahead of schedule for several automakers — including a knockoff of the lovable Volkswagen Microbus — you may be wondering if it’s finally time to buy or lease one.

Here are the essential questions to answer before you do.

(Full disclosure: I’m a convert myself after six years and 70,000 gas-free miles.)

1. Can you afford an electric car?
Electric vehicles tend to be pricy to buy but can be more affordable to lease. Finding federal, state and local government incentives can also reduce sticker shock. And, even if the monthly payment is higher than a comparable gas car, operating costs are lower.

Gas vehicles cost an average of $3,356 per year to fuel, tax and insure, while electric cost just $2,722, according to a study by Self Financial, and Consumer Reports finds EVs save money in the long run too. Find out how much you can save with the Department of Energy calculator.

2. How far do you need to drive on a single charge?
Although almost 60 percent of all car trips in America were less than 6 miles in 2017, according to the Department of Energy, the phrase “range anxiety” scared many would-be early adopters.

Teslas became popular in part because they offered 250 miles of range. But the range of many electric vehicles between charges is now over 200 miles; even the modestly priced Chevrolet Bolt can travel 259 miles on a single charge.

Still, electric vehicles have a “road trip problem,” according to Josh Sadlier, director of content strategy for car site Edmunds.com. “If you like road trips, you almost have to have two cars — one for around town and one for longer trips,” he says.

3. Where will you charge it?
If you live in an apartment without a charging station, this could be a deal breaker.

The number of public chargers increased by 60 percent worldwide in 2019, according to the International Energy Agency. While these stations — some of which are free — are more available, most electric vehicle owners install a home station for faster charging.

Electric vehicles can be charged by plugging into a common 120-volt household outlet, but it’s slow, and understanding charging costs can help you plan home use. To speed up charging, many electric vehicle owners wind up buying a 240-volt charging station and having an electrician install it for a total cost of $1,200, according to the home remodeling website Fixr.

4. What will you use the car for?
While there are a few luxury electric SUVs on the market, most electric vehicles are smaller sedans or hatchbacks with limited cargo capacity. However, the coming wave of electric cars are more versatile, and many experts expect that within a decade these options will be commonplace, including vans, such as the Microbus, and trucks, such as an electric version of the popular Ford F-150 pickup.

5. Do you enjoy performance?
This is where electric vehicles really shine. According to automotive experts, electric cars beat their gas counterparts in these ways:

Immediate response with great low-end acceleration, particularly in the 0-30 mph range.
Sure-footed handling due to the heavy battery mounted under the car, giving it a low center of gravity.
No “shift shock” from changing gears in a conventional gas car’s transmission.
Little noise except from the wind and tires.

Other factors
Once you consider the big questions, here are other reasons to make an electric car your next choice:

Reduced environmental guilt. There is a persistent myth that electric vehicles simply move the emissions from the tailpipe to the power generating station. Yes, producing electricity produces emissions, but many electric vehicle owners charge at night when much of the electricity would otherwise be unused. According to research published by the BBC and evidence that they are better for the planet in many scenarios electric cars reduce emissions by an average of 70 percent, depending on where people live.

Less time refueling. It takes only seconds to plug in at home, and the electric vehicle will recharge while you’re doing other things. No more searching for gas stations and standing by as your tank gulps down gasoline.

No oil changes. Dealers like a constant stream of drivers coming in for oil changes so they can upsell other services. Electric vehicles have fewer moving parts and require fewer trips to the dealership for maintenance.

Carpool lanes and other perks. Check your state regulations to see if an electric vehicle gets you access to the carpool lane, free parking or other special advantages.

Enjoy the technology. Yes, electric vehicles are more expensive, but they also tend to offer top-of-the-line comfort, safety features and technology compared with their gas counterparts.

Related News

• Electricity Forum News

• EV Infrastructure News

U.S. EV Sales Growth reflects rising consumer demand, expanding market share, new tax credits, and robust charging infrastructure, as automakers boost output and quarterly sales under the Inflation Reduction Act drive adoption across states.

Key Points

It is the rise in U.S. EV sales and market share, driven by incentives, charging growth, and automaker investment.

✅ Quarterly EV sales and share have risen since Q3 2021.

✅ Share topped 10% in Q3 2023, with states far above.

✅ IRA credits and chargers lower costs and boost adoption.

Contrary to any skepticism, the demand for electric vehicles (EVs) in the United States is not dwindling. Data from the Alliance for Automotive Innovation highlights a significant and ongoing increase in EV sales from 2021 through the third quarter of 2023. An upward trend in quarterly sales (depicted as bars on the left axis) and EV sales shares (illustrated by the red line on the right axis) is evident. Sales surged from about 125,000 in Q1 2021 to 185,000 in Q4 2021, and from around 300,000 in Q1 2023 to 375,000 by Q3 2023. Notably, by Q3 2023, annual U.S. EV sales exceeded 1 million for the first time, a milestone often cited as the tipping point for mass adoption in the U.S., marking a 58% increase over the same period in 2022.

EV sales have shown consistent quarterly growth since Q3 2021, and the proportion of EVs in total light-duty vehicle sales is also on the rise. EVs’ share of new sales increased from roughly 3% in Q1 2021 to about 7% in 2022, and further to over 10% in Q3 2023, though they are still behind gas cars in overall market share, for now. For context, according to the U.S. Environmental Protection Agency’s Automotive Trends Report, EVs have reached a 10% market share more quickly than conventional hybrids without a plug, which took about 25 years.

State-level data also indicates that several states exceed national averages in EV sales. California, for example, saw EVs comprising nearly 27% of sales through September 2023, even as a brief Q1 2024 market share dip has been noted nationally. Additionally, 12 states plus the District of Columbia had EV sales shares between 10% and 20% through Q3 2023.

EV sales data by automaker reveal that most companies sold more EVs in Q2 or Q3 2023 than in any previous quarter, mirroring global growth that went from zero to 2 million in five years. Except for Ford, each automaker sold more EVs in the first three quarters of 2023 than in all of 2022. EV sales in Q3 2023 notably increased compared to Q3 2022 for companies like BMW, Tesla, and Volkswagen.

Despite some production scalebacks by Ford and General Motors, these companies, along with others, remain dedicated to an electric future and expect to sell more EVs than ever. The growing consumer interest in EVs is also reflected in recent surveys by McKinsey, J.D. Power, and Consumer Reports, and echoed in Europe where the share of electric cars grew during lockdown months, showing an increasing intent to purchase EVs and a declining interest in gasoline vehicles.

Furthermore, the Inflation Reduction Act of 2022 introduces new tax credits, potentially making EVs more affordable than gasoline counterparts. Investments in charging infrastructure are also expected to increase, especially as EV adoption could drive a 38% rise in U.S. electricity demand, with over $21 billion allocated to boost public chargers from around 160,000 in 2023 to nearly 1 million by 2030.

The shift to EVs is crucial for reducing climate pollution, enhancing public health, and generating economic benefits and jobs, and by 2021 plug-in vehicles had already traveled 19 billion miles on electricity, underscoring real-world progress toward these goals. The current data and trends indicate a robust and positive future for EVs in the U.S., reinforcing the need for strong standards to further encourage investment and consumer confidence in electric vehicles.

Related News

• Electricity Forum News

• EV Infrastructure News

UK Renewable Grid Connection Delays threaten the 2035 zero-carbon electricity target as National Grid queues stall wind and solar projects, investors, and infrastructure, slowing clean energy deployment, curtailing capacity build-out, and risking net-zero progress.

Key Points

Prolonged National Grid queues delaying wind and solar connections, jeopardizing the UK's 2035 clean power target.

✅ Up to 15-year waits for grid connections

✅ Over £200bn projects stuck in the queue

✅ Threatens zero-carbon electricity by 2035

The UK currently has a 2035 target for 100% of its electricity to be produced without carbon emissions, while Ireland's green electricity progress offers a nearby benchmark within the next four years.

But meeting the target will require a big increase in the number of renewable projects across the country. It is estimated as much as five times more solar and four times as much wind is needed, with growth in UK offshore wind expected to play a key role here.

The government and private investors have spent £198bn on renewable power infrastructure since 2010, alongside European wind investments recorded last year. But now energy companies are warning that significant delays to connect their green energy projects to the system will threaten their ability to bring more green power online.

A new wind farm or solar site can only start supplying energy to people's homes once it has been plugged into the grid.

Energy companies like Octopus Energy, one of Europe's largest investors in renewable energy, say they have been told by National Grid that they need to wait up to 15 years for some connections, even as a new 10 GW contract aims to speed UK grid additions - far beyond the government's 2035 target.

'Longest grid queues in Europe'
There are currently more than £200bn worth of projects sitting in the connections queue, the BBC has calculated.

Around 40% of them face a connection wait of at least a year, according to National Grid's own figures. That represents delayed investments worth tens of billions of pounds, reflecting stalled grid spending that slows renewable rollouts.

"We currently have one of the longest grid queues in Europe," according to Zoisa North-Bond, chief executive of Octopus Energy Generation.

The problem is so many new renewable projects are applying for connections, the grid cannot keep up with required network expansion such as new pylons in Scotland being discussed nationwide.

The system was built when just a few fossil fuel power plants were requesting a connection each year, but now there are 1,100 projects in the queue, a challenge mirrored by U.S. grid hurdles in moving toward 100% renewables today.

Related News

• Electricity Forum News

• Renewable Energy News

Electric Car Motors convert electricity to torque via rotor-stator magnetic fields, using AC/DC inverters, permanent magnets or induction designs; they power EV powertrains efficiently and enable regenerative braking for energy recovery and control.

Key Points

Electric car motors turn electrical energy into wheel torque using rotor-stator fields, inverters, and AC or DC control.

✅ AC induction, PMSM, BLDC, and reluctance architectures explained

✅ Inverters manage AC/DC, voltage, and motor speed via frequency

✅ Regenerative braking recovers energy and reduces wear

When was the last time you stopped to think about how electric cars actually work, especially if you're wondering whether to buy an electric car today? We superfans of the car biz have mostly developed a reasonable understanding of how combustion powertrains work. Most of us can visualize fuel and air entering a combustion chamber, exploding, pushing a piston down, and rotating a crankshaft that ultimately turns the wheels. We generally understand the differences between inline, flat, vee-shaped, and maybe even Wankel rotary combustion engines.

Mechanical engineering concepts such as these are comparatively easy to comprehend. But it's probably a fair bet to wager that only a minority of folks reading this can explain on a bar napkin exactly how invisible electrons turn a car's wheels or how a permanent-magnet motor differs from an AC induction one. Electrical engineering can seem like black magic and witchcraft to car nuts, so it's time to demystify this bold new world of electromobility, with the age of electric cars arriving ahead of schedule.

How Electric Cars Work: Motors
It has to do with magnetism and the natural interplay between electric fields and magnetic fields. When an electrical circuit closes allowing electrons to move along a wire, those moving electrons generate an electromagnetic field complete with a north and a south pole. When this happens in the presence of another magnetic field—either from a different batch of speeding electrons or from Wile E. Coyote's giant ACME horseshoe magnet, those opposite poles attract, and like poles repel each other.

Electric motors work by mounting one set of magnets or electromagnets to a shaft and another set to a housing surrounding that shaft. By periodically reversing the polarity (swapping the north and south poles) of one set of electromagnets, the motor leverages these attracting and repelling forces to rotate the shaft, thereby converting electricity into torque and ultimately turning the wheels, in a sector where the electric motor market is growing rapidly worldwide. Conversely—as in the case of regenerative braking—these magnetic/electromagnetic forces can transform motion back into electricity.

How Electric Cars Work: AC Or DC?
The electricity supplied to your home arrives as alternating current (AC), and bidirectional charging means EVs can power homes for days as needed, so-called because the north/south or plus/minus polarity of the power changes (alternates) 60 times per second. (That is, in the United States and other countries operating at 110 volts; countries with a 220-volt standard typically use 50-Hz AC.) Direct current (DC) is what goes into and comes out of the + and - poles of every battery. As noted above, motors require alternating current to spin. Without it, the electromagnetic force would simply lock their north and south poles together. It's the cycle of continually switching north and south that keeps a motor spinning.

Today's electric cars are designed to manage both AC and DC energy on board. The battery stores and dispenses DC current, but again, the motor needs AC. When recharging the battery, and with increasing grid coordination enabling flexibility, the energy comes into the onboard charger as AC current during Level 1 and Level 2 charging and as DC high-voltage current on Level 3 "fast chargers." Sophisticated power electronics (which we will not attempt to explain here) handle the multiple onboard AC/DC conversions while stepping the voltage up and down from 100 to 800 volts of charging power to battery/motor system voltages of 350-800 volts to the many vehicle lighting, infotainment, and chassis functions that require 12-48-volt DC electricity.

How Electric Cars Work: What Types Of Motors?
DC Motor (Brushed): Yes, we just said AC makes the motor go around, and these old-style motors that powered early EVs of the 1900s are no different. DC current from the battery is delivered to the rotor windings via spring-loaded "brushes" of carbon or lead that energize spinning contacts connected to wire windings. Every few degrees of rotation, the brushes energize a new set of contacts; this continually reverses the polarity of the electromagnet on the rotor as the motor shaft turns. (This ring of contacts is known as the commutator).

The housing surrounding the rotor's electromagnetic windings typically features permanent magnets. (A "series DC" or so-called "universal motor" may use an electromagnetic stator.) Advantages are low initial cost, high reliability, and ease of motor control. Varying the voltage regulates the motor's speed, while changing the current controls its torque. Disadvantages include a lower lifespan and the cost of maintaining the brushes and contacts. This motor is seldom used in transportation today, save for some Indian railway locomotives.

Brushless DC Motor (BLDC): The brushes and their maintenance are eliminated by moving the permanent magnets to the rotor, placing the electromagnets on the stator (housing), and using an external motor controller to alternately switch the various field windings from plus to minus, thereby generating the rotating magnetic field.

Advantages are a long lifespan, low maintenance, and high efficiency. Disadvantages are higher initial cost and more complicated motor speed controllers that typically require three Hall-effect sensors to get the stator-winding current phased correctly. That switching of the stator windings can result in "torque ripple"—periodic increases and decreases in the delivered torque. This type of motor is popular for smaller vehicles like electric bikes and scooters, and it's used in some ancillary automotive applications like electric power steering assist.

Permanent-Magnet Synchronous Motor (PMSM): Physically, the BLDC and PMSM motors look nearly identical. Both feature permanent magnets on the rotor and field windings in the stator. The key difference is that instead of using DC current and switching various windings on and off periodically to spin the permanent magnets, the PMSM functions on continuous sinusoidal AC current. This means it suffers no torque ripple and needs only one Hall-effect sensor to determine rotor speed and position, so it's more efficient and quieter.

The word "synchronous" indicates the rotor spins at the same speed as the magnetic field in the windings. Its big advantages are its power density and strong starting torque. A main disadvantage of any motor with spinning permanent magnets is that it creates "back electromotive force" (EMF) when not powered at speed, which causes drag and heat that can demagnetize the motor. This motor type also sees some duty in power steering and brake systems, but it has become the motor design of choice in most of today's battery electric and hybrid vehicles.

Note that most permanent-magnet motors of all kinds orient their north-south axis perpendicular to the output shaft. This generates "radial (magnetic) flux." A new class of "axial flux" motors orients the magnets' N-S axes parallel to the shaft, usually on pairs of discs sandwiching stationary stator windings in between. The compact, high-torque axial flux orientation of these so-called "pancake motors" can be applied to either BLDC or PMSM type motors.

AC Induction: For this motor, we toss out the permanent magnets on the rotor (and their increasingly scarce rare earth materials) and keep the AC current flowing through stator windings as in the PMSM motor above.

Standing in for the magnets is a concept Nikola Tesla patented in 1888: As AC current flows through various windings in the stator, the windings generate a rotating field of magnetic flux. As these magnetic lines pass through perpendicular windings on a rotor, they induce an electric current. This then generates another magnetic force that induces the rotor to turn. Because this force is only induced when the magnetic field lines cross the rotor windings, the rotor will experience no torque or force if it rotates at the same (synchronous) speed as the rotating magnetic field.

This means AC induction motors are inherently asynchronous. Rotor speed is controlled by varying the alternating current's frequency. At light loads, the inverter controlling the motor can reduce voltage to reduce magnetic losses and improve efficiency. Depowering an induction motor during cruising when it isn't needed eliminates the drag created by a permanent-magnet motor, while dual-motor EVs using PMSM motors on both axles must always power all motors. Peak efficiency may be slightly greater for BLDC or PMSM designs, but AC induction motors often achieve higher average efficiency. Another small trade-off is slightly lower starting torque than PMSM. The GM EV1 of the mid-1990s and most Teslas have employed AC Induction motors, despite skepticism about an EV revolution in some quarters.

Reluctance Motor: Think of "reluctance" as magnetic resistance: the degree to which an object opposes magnetic flux. A reluctance motor's stator features multiple electromagnet poles—concentrated windings that form highly localized north or south poles. In a switched reluctance motor (SRM), the rotor is made of soft magnetic material such as laminated silicon steel, with multiple projections designed to interact with the stator's poles. The various electromagnet poles are turned on and off in much the same way the field windings in a BLDC motor are. Using an unequal number of stator and rotor poles ensures some poles are aligned (for minimum reluctance), while others are directly in between opposite poles (maximum reluctance). Switching the stator polarity then pulls the rotor around at an asynchronous speed.

A synchronous reluctance motor (SynRM) doesn't rely on this imbalance in the rotor and stator poles. Rather, SynRM motors feature a more distributed winding fed with a sinusoidal AC current as in a PMSM design, with speed regulated by a variable-frequency drive, and an elaborately shaped rotor with voids shaped like magnetic flux lines to optimize reluctance.

The latest trend is to place small permanent magnets (often simpler ferrite ones) in some of these voids to take advantage of both magnetic and reluctance torque while minimizing cost and the back EMF (or counter-electromotive force) high-speed inefficiencies that permanent-magnet motors suffer.

Advantages include lower cost, simplicity, and high efficiency. Disadvantages can include noise and torque ripple (especially for switched reluctance motors). Toyota introduced an internal permanent-magnet synchronous reluctance motor (IPM SynRM) on the Prius, and Tesla now pairs one such motor with an AC induction motor on its Dual Motor models. Tesla also uses IPM SynRM as the single motor for its rear-drive models.

Electric motors may never sing like a small-block or a flat-plane crank Ferrari. But maybe, a decade or so from now, we'll regard the Tesla Plaid powertrain as fondly as we do those engines, even as industry leaders note that mainstream adoption faces hurdles, and every car lover will be able to describe in intimate detail what kind of motors it uses.
 

Related News

• Electricity Forum News

• EV Infrastructure News