Start Your Engines: EVs are Becoming More Efficient

Electric vehicles (EVs) are rapidly gaining market share in the automotive industry. In 2020, EVs accounted for less than 5% of all new auto sales; that number rose to 14% in 2022. Will the EV market plateau or continue to make gains?

We’re facing a once-in-a-lifetime industry paradigm shift in vehicle architecture. If manufacturers can design and implement EVs with higher levels of efficiency while consolidating the footprint of electronic assemblies — and do all of this cheaper than the current model requires — the market will continue its ascent. In this article, we’ll explore an EV industry on the precipice of achieving these goals on multiple levels.

A gas-powered car and its owner spend around five minutes at the gas pump, and drivers have been conditioned to expect this experience when refueling. Can similar times be achieved at public EV charging stations?

By the beginning of 2023, there were 130,000 charging points across the United States and 2.7 million worldwide. Public charging stations are seeing advances that allow for faster-charging power and speed. Progress in charging technology has facilitated enhanced power delivery to EVs, with higher power outputs that can furnish more electricity to the vehicle, decreasing charging times. 

EV charging infrastructure has improved in terms of power capacity. Fast chargers with higher power outputs, such as DC fast chargers, are now more widespread. These chargers can deliver more electrical power to the vehicle, resulting in more efficient charging for time-crunched motorists.

A growing number of charging stations now also feature dynamic charging capabilities, allowing power adjustment based on the battery's state of charge. This dynamic charging ensures that the battery receives the optimum charging rate at all times, maximizing charging efficiency and minimizing charging time.

Smaller component footprints and weight reduction throughout electronics systems play a critical role in making EVs more efficient and cost-effective.

Smaller Package Size

Miniaturization can help maximize performance when space is at a premium. Fitting all the electronic components into an EV is complex, but design engineers are finding ways to make them more compact. Wire harness packages are driven by wire size and voltage; a vehicle's overall weight can be reduced by making these harnesses smaller and more efficient.

Reduced Weight

Although thicker than traditional copper wire, opting for aluminum cable contributes to weight and cost savings. And, despite the need for larger gauge wire to conduct the same amount of energy, aluminum wire weighs only 30 percent of the weight of copper. Additionally, aluminum wire costs up to half as much as copper wire.

Manufacturers have begun using metal alloys, composites and polymers to decrease the weight of internal electronic systems further. Using these materials strategically reduces weight without compromising functionality and durability.

Combined Effects

By reducing weight and package size and opting for more cost-effective materials where appropriate, EVs can be more efficient without sacrificing performance. The value of optimizing each component across the entire vehicle assembly adds up to real efficiency gains.

Design engineers are working diligently toward achieving lower temperatures in their electrical systems. For instance, connectors used in EVs are being optimized for lower temperatures, allowing for the use of lower-cost resins without compromising performance. This optimization eliminates the over-engineering of connectors, reducing costs while maintaining reliability and functionality.

Electronic components with smaller footprints reduce heat generation, allowing for better heat dissipation. Heat sinks, using materials with high thermal conductivity, absorb and dissipate the heat created by electrical components. Insulation techniques also help to minimize the heat transfer between hot and cold areas inside the EV. This prevents thermal degradation, allowing each system to perform as designed. Combining these thermal techniques allows internal EV components to withstand high operating temperatures without compromising performance.

An EV’s battery management system (BMS) plays a crucial role in overseeing battery storage systems by employing various control techniques like charge-discharge control, temperature regulation and monitoring cell potential, current and voltage. These measures effectively enhance the safety and longevity of the Energy Management System (EMS) by ensuring proper supervision and continuous monitoring.

By combining battery state of charge accuracy, cell balancing, thermal management and protection against overcharge and discharge, an advanced BMS helps the entire vehicle efficiently distribute and optimize energy levels. In a recent Molex survey of over 800 design engineers, 22% reported that battery packs pose the biggest challenge when designing or implementing EV power systems. The battery pack was ranked as the second biggest challenge behind in-vehicle power electronics.

Designers are adopting higher-voltage power, using 48 volts instead of 12 to engage sensors, motors, ECUs and other components. Higher voltages deliver the same amount of energy with less current, enabling thinner and lighter cables. Similarly, EV power trains are moving to higher-voltage architectures and adopting more efficient controller and wiring setups.

Using all the advancements discussed above, EVs can have more compact, lighter-weight electronic components that enhance vehicle efficiencies. This is the next chapter the EV industry has been waiting for.

When EV manufacturers need smaller, more efficient and lighter-weight systems, Molex provides them with a comprehensive lineup of miniaturized solutions to help enable dependable functionality. As the demand for more sophisticated electronic systems within EVs continues, Molex’s proven expertise will help drive the EV market forward.