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The government’s Climate Action Plan envisages a large role for electric transport, and John Hayes — a senior lecturer at University College Cork and an expert in the area — guides us through its origins and whether the technology can replace our petrol engines.

The dark side of energy addiction


Electric cars once played a substantial role in transporting the public, with about as many electric cars as petrol cars being sold in the United States in 1900.

The petrol car of the time was seen as dirty, dangerous, and unreliable, while the electric car was perceived as quiet and safe, albeit with limited range.

This was all to change with the low-cost production of the petrol Model T by Henry Ford in 1907, and later with the replacement of the manual engine crank by the electric starter in 1912. Diesel engines featured in the 1920s and grew in popularity for heavy vehicles, and much later for cars in Europe.

Thus, over a number of decades, the world of transportation had changed completely – long distance, reliable, low-cost driving was available to the masses.

At the same time, the world was electrifying, with the ac grids, created by Nicola Tesla, rapidly expanding around the world.

Access to incredible amounts of energy and the energy-consuming technologies to propel, warm, cook, clean, communicate and entertain, fundamentally changed the way that many humans lived around the planet. Economies could grow and humanity could propagate like never before.

All this access to energy also came with a dark side in the forms of energy addiction, wars, pollution and environmental damage. Pollution bedevilled our cities. Carbon emissions and, even worse, methane emissions expanded globally and contributed to global warming.

The renaissance takes many forms: battery, hybrid and fuel cell


A lot has changed in the last 40 years and will continue to change.

I was part of the engineering team in Los Angeles that brought the General Motors EV1 to market in 1996. This was to be the first production electric car of the modern era, and it pioneered a path for others to follow.

Prior to this, Professor John Goodenough had invented the lithium-ion battery in 1979. These batteries initially powered laptop computers but, with time, have powered the massive global expansion of mobile phones and smart devices, fundamentally changing how we communicate, learn and entertain.

John Hayes with Professor John Goodenough, who invented the lithium-ion battery in 1979.

The lithium-ion battery was very successfully adopted for cars in the 2000s in an effort led by the transformative and extraordinary Elon Musk of Tesla Motors.

In October 2019, Professor John Goodenough was awarded the Nobel Prize in Chemistry, together with Stanley Whittingham and Akira Yoshino, for the invention of the Li-ion battery.

The continuing electrification of the vehicle is inevitable due to the high efficiency, the reduced emissions, and the use of clean energy.

The electric car can take several forms so that we are not overly dependent on any one technology. There are four different types of electric vehicles: battery, such as the Nissan Leaf; hybrid, such as the Toyota Prius; plug-in hybrid, such as the Mitsubishi Outlander; and fuel cell, such as the Toyota Mirai.

All of these vehicle types feature batteries and electric motors, which can independently propel the vehicle using electricity. A fifth type of vehicle is the mild hybrid, which uses conventional petrol or diesel engines for propulsion, but increases the use of electrics to decrease fuel consumption and emissions.

All of these technologies, except for the fuel cell vehicle, are available today in Ireland.

Hybrid and hydrogen vehicles are options for today and tomorrow


Petrol and diesel hybrid vehicles consume fossil fuels but use electric technology to require less fuel to propel the vehicle, than would a conventional petrol or diesel vehicle.

While hybrid vehicles emit more carbon dioxide while driving than the equivalent battery vehicle emits due to the generation of electricity, battery vehicles result in greater emissions during manufacturing.

Thus, given the Irish grid today and international vehicle manufacturing, hybrid and battery vehicles have similar carbon footprints, and both are lower than the equivalent diesel or petrol vehicle.

This situation will change with time. Wind energy has been the success story in Ireland over the past two decades, with renewables now providing more than 30 per cent of our electricity.

The future of energy generation in Ireland will be even greener. Electrical connections to the UK and France will provide access to the excess renewable and nuclear energies elsewhere.

The fuel cell vehicle is powered by hydrogen, a fuel which can store great amounts of energy on board and allow for rapid refuelling. The hydrogen can be produced using fossil fuels, but more importantly, it can also be produced by renewable electrical power.

Fuel cell vehicles have the lightweight energy storage required for heavy vehicles. Unlike the battery vehicles, which can be fuelled with a home charger, fuel cell vehicles require an infrastructure similar to the petrol station of today.

China, a heavyweight today in battery electric vehicles, is now also heavily investing in fuel cell vehicles in order to have clean long-distance transport.

Electric car will be evolutionary, and not revolutionary


It is also important to ask what can go wrong with this vision. The diesel emissions scandal has been a hard lesson in shaping the public’s purchases.

From 2008, diesel engines were incentivised in order to reduce carbon emissions, while the harmful toxic emissions of these engines in urban environments were obviously not a major consideration... until the exposure in 2015 of the wide-spread cheating by Volkswagen.

This second coming of the electric car will be evolutionary, and not revolutionary. The capital costs will be enormous as the electric grid is transformed and the fleet of vehicles is turned over.

Norway is often discussed as a model country for electric vehicle sales, largely due to its subsidies and incentives.

Norway sits on significant fossil fuel reserves and a sovereign wealth fund of more than $1 trillion. A total of 98 per cent of Norway’s electricity is already green and bountiful, based on a massive dam network, with Norwegians consuming several times the electricity of the Irish.

Ireland, on the other hand, gets 30 per cent of its electricity from renewables, will see the Corrib gas field go dry in several years, and has a government debt of €200 billion. It would be great to have Norway’s resources!

The battery is the strength of electric vehicles, but also the weakness. The technology has developed amazingly, with 60 kWh of battery storage available on the latest models with more than 400km of range.

However, sourcing of critical materials, such as lithium and cobalt, together with the energy and carbon intensities of production, raise questions as to the sustainability of the batteries themselves.

Advances in the technology appear marginal when considered from a high-tech perspective, but are actually impressive when considered from a power or energy perspective.

Improvements will continue in reducing size and cost, and significant gains can be made in terms of reducing the carbon footprint and improving battery recyclability and reuse.

We will learn over the next decade of the 2020s which of the solutions are viable and sustainable as economies of scale and supply chains develop. Car sharing and autonomous vehicles will also feature.

All going well, as the current young generation of teenagers enter the 2030s, they will have environmentally friendly, sustainable transportation options which their parents never dreamt of.

Author: John Hayes is a senior lecturer at University College Cork and previously worked in the automotive industry. He is the lead author on 'Electric Powertrain: Energy Systems, Power Electronics and Drives for Hybrid, Electric and Fuel Cell Vehicles' by Hayes and Goodarzi, and published by John Wiley & Sons in January 2018.

The second coming of the electric car

To pave the way for the seamless automation of machines and systems, Festo offers a unique range of solutions we help you to connect your automation components and machines so that they interact perfectly at all times, mechanically, electrically and intelligently.

Put your trust in a partner who has being setting technological standard for decades, whether in pneumatic or electric automation.

Servo drive CMMT-AS and Servo motor EMMT-AS.

And don’t expect anything less than a comprehensive offer of solutions, from mechanical systems, integrated motion, control solution and subsystems to modern cloud solutions for a variety of industries.

Complete drive system, consisting of servo drive and servo motor, with seamless connectivity in hardware and software.

The servo drive CMMT-AS and servo motor EMMT-AS are connected via single-cable solution and can be commissioned quickly and easily using the Festo Automation suite.

  • For point-to-point and interpolating motion with focus on dynamic motion and precise positioning.
  • Complete integration into other third-party control concepts or directly on the control system CPX-E from Festo.
  • Compact and optimised package design as well as clever 2-sided operating and connection concept ensure low space requirements in the control cabinets.

Click here for the servo drive package.

Optimised motion series: a low-cost system with optimised performance. It comprises a mechanical system (motor controller) with integrated web browser technology and matching connecting cables.

The electrical positioning system: Optimised Motion Series.

As a single electric cylinder toothed belt axis or rotary module as well as cost-effective multi-axis solution for simple handling tasks.

Another major plus: you can configure, order and commission using just 1 type code.

Find out more here.

The simplicity of pneumatics is now combined for the first time with the advantages of electric automation thanks to the Simplified Motion Series.

These integrated drives are the perfect solution for all users who are looking for an electric alternative for very simple movement and positioning tasks, but don’t want the commissioning process for traditional electric drive system that can often be quite complex.

The electrical positioning system Simplified Motion Series.

There is no need for any software since operation is simply based on the 'plug and work' principle.

The simplified functionality makes the drives ideal for simple movements between two mechanical ends positioning without having to sacrifice optimised motion characteristics, gently cushioned retracting into the end positions or simplified press-fitting and clamping functions.

Find out more here.

Contact us: Sales ROI: 01-295 49 55; Sales NI: +44(0) 1604 667000; email: sales_ie@festo.com and www.festo.ie

Seamless connectivity is electric automation without any compromise

The world has moved on – and quickly - the days of old-fashioned portfolio project management (PPM) are over, writes Philip Martin.

You can no longer manage your portfolio of projects using MS Excel spreadsheets, PowerPoint reports and emails and expect your organisation to be a competitive leader.

Powerful integrated enterprise solution


These days, you need a powerful integrated enterprise solution that is configurable, intuitive and easy for the entire team to use. More and more of our clients are coming to this realisation.

One of the most interesting projects we’re working on at the moment is with a US firm, Automated Logic Corporation, or ALC for shorthand.

ALC is a global leader in building automation systems, and is a part of UTC Carrier, a division of United Technologies Corp, which is one of the largest providers to the aerospace and building systems industries worldwide.

ALC choose to work with us because they wanted to install our Cora PPM solution. They needed a system to help them better manage their resourcing, their capacity management and to streamline the workflows they operate with their licensed vendors.

Essentially, they required a digitised and cloud-based collaboration tool to deploy across the organisation. What our Cora PPM solution offered them was a platform that assisted them in standardising work processes across all their business units so they could operate more efficiently and, for example, improve the execution transparency of projects at all tiers of the organisation. This was key.

Create dynamic Gantt-style scheduling chart


Once Cora PPM has been implemented, ALC are now able to import the detailed scope of any awarded project and create a dynamic Gantt-style scheduling chart, which sets all projects across the United States off on a level footing.

It provides a convenient way to access documentation and standard templates for every project. ALC’s business executives are able to delve instantly into the detail of each portfolio of work on major projects, delivering significant time savings and making them more competitive.

Mark Ruettiger, North America operations manager for automated logic, has summed up the benefits of the partnership: “We chose to work with Cora Systems because it’s proven to be one of the more innovative software companies in the industry and it has an extremely customisable PPM solution, which is what we needed – a solution that would fit to the way our business processes operate.

"Everything from being able to do our monthly forecasting to our cost reviews are all very detailed and specific. We’ve had a good, collaborative working relationship to date. It’s been a positive experience.”

It is gratifying for us that we’re already seeing results from the implementation and it has encouraged UTC, which is ALC’s parent company, to roll-out the solution to other divisions of the business.

Author: Philip Martin is CEO of Cora Systems. For an introduction to Cora PPM, including a short overview video, click here: https://corasystems.com/takeatour

How an American building automation systems provider improved its project forecasting and standardised workflow processes

Machine builders and operators for bulk handling know all too well that bulk handling processes are anything but trivial – excellent bulk handling requires professionalism.

And professional systems can be designed more efficiently and with higher quality using intelligent automation solutions from Festo.

OEMs and end users increasingly rely on modular production systems, which offer a flexible, individual and maintenance-friendly alternative to conventional systems.

Incorporating conventional systems into monolithic automation solutions is often a time-consuming task.

However, a high degree of system modularity also requires new automation solutions – here Festo uses the principle of modular automation.

More flexibility through scalable systems


Automation solutions from Festo are particularly suitable for bulk handling systems in which a large number of different raw materials are stored and therefore a large number of filling stations have to be controlled.

While the entire system is usually controlled centrally by one process control system, modular systems can be scaled, expanded and adapted almost infinitely by simply integrating autonomous modules into the existing production system. And this is where solutions from Festo can help

Autonomous modules with their own intelligence


When it comes to modular automation, the electrical terminal CPX with integrated controller CEC and valve terminal MPA play a central role in the automation of production modules.

This makes it possible to provide each system module with a decentralised controller, giving it its own intelligence.

The modules are thus autonomous and can easily be added to or removed from the overall system as required.

There are already concrete applications for handling bulk materials, including filling systems with up to 60 filling stations.

Each filling station is equipped with its own decentralised controller and can thus be integrated more quickly into the overall system; this significantly reduces the risk of errors in the actual production process.

The process control system becomes leaner because only the initial commands for the modules are needed, and then all detailed processes are run directly via the decentralised CPX CECs.

As a result, it is possible to create modules individually from stock and test them in advance; this improves the supply capability of the OEMs, accelerates commissioning and reduces the software complexity of the system.

The bottom line: thanks to modular automation from Festo, manufacturers and operators of bulk handling systems will not just be able to achieve massive cost savings, but they can also improve the productivity of their systems by using autonomous modules.

The strict consideration and implementation of the NAMUR recommendation 'NE 148' offers you additional peace of mind.

Further information can be found at: https://www.festo.com/cms/en-gb_ie/70166.htm

Modular automation from Festo makes bulk handling more efficient

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