Abstract
The future of e-mobility is being shaped by innovations in power systems, connectivity, and sustainable design. This article explores key technologies driving the industry forward, featuring insights from experts on battery optimization, sensor integration, and the role of smart connectivity. Through the case study of the Lightning Board, we dive into practical solutions for enhancing performance and reducing costs in light electric vehicles. Engineers and industry players alike will gain valuable knowledge on how to future-proof e-mobility designs and stay ahead in a rapidly evolving market.
Panelists
Riccardo Collura
Power Specialist
Davide Osto
Sensors Specialist
Rabee Alhayek
Connectivity Specialist
Lazina Rahman
IoT/Connectivity Specialist
Mediator
Introduction
In the journey towards a more sustainable future, electric mobility is emerging as a key pillar of transformation. With consumers and industries prioritizing green solutions, the global e-mobility market was valued at USD 551.57 billion in 2024 and is projected to surge to USD 4,364.85 billion by 2032 at a CAGR of 29.9%. *
This rapid growth is fueled by the market trends that engineers and developers are quick to address and tackle with creativity and innovation. In the electronics industry, it takes a complex interaction between power solutions, sensors, and connectivity to design the next generation of e-mobility—yes, electric vehicles like cars, but also anything from e-scooters and e-bikes to tractors and rail solutions.
Battery performance, power optimization, cutting-edge sensors integrations and wireless solutions, all play a role in the e-mobility sector, pushing possibilities and creating new challenges.
To explore these opportunities and unravel the intricacies of e-mobility design, we gathered a panel of engineers from diverse areas of expertise to discuss the topics in depth:
- Riccardo Collura, Power Specialist
- Davide Osto, Sensors Specialist
- Rabee Alhayek, Connectivity Specialist
- Lazina Rahman (IoT/Connectivity Specialist) as our mediator
Throughout the panel, we unpacked key questions and the intersection of power management, sensor technology, and connectivity, diving into the challenges and the innovations that are shaping the industry. The shared insights provide a comprehensive view of where e-mobility is today—and where it’s heading tomorrow.
This series captures the heart of their conversation in four detailed sections:
- General Challenges in E-Mobility Design
- Innovation and Integration in E-Mobility
- Lightning Board: A Case Study in E-Mobility
- Future Trends in E-Mobility
Read along and explore how engineers and designers are creating the future of mobility, balancing innovation with sustainability and practicality.
Methodology disclaimer and market size source:
This report is edited, structured, and verified by the Future Content Development team based on the insights from our panel discussions. Transcripts were refined and polished with the assistance of AI, blending automation and human expertise to deliver a clear and accurate final piece.
*Source: Fortune Business Insights – Electric Mobility Market Size, Share & Industry Analysis, By Product (Electric Car, Electric Motorcycle, Electric Scooter, Electric Bike, and Others), By Voltage (Less than 24V, 24V, 36V, 48V, and Greater than 48V), By Battery (Sealed Lead Acid, NiMH, and Li-ion), and Regional Forecast Period, 2024-2032
https://www.fortunebusinessinsights.com/electric-mobility-market-106485
General Challenges in E-Mobility Design
The e-mobility revolution is shaping transportation and paving the way in energy innovation. However, each innovation comes with its challenges, and designing next-generation devices is not the exception. Hurdles span from power systems to sensor integration, and connectivity solutions, each playing a critical role in creating efficient, reliable, and user-friendly electric mobility solutions.
To go over these challenges, we categorized them into three core areas: Power, Sensors, and Connectivity.
Challenges in Power
- Battery Technology
One of the most significant challenges is improving battery energy density. Current batteries are heavy and occupy considerable space, limiting the range and performance of electric vehicles (EVs), e-bikes, and scooters. Engineers must innovate to make batteries lighter and more compact without sacrificing efficiency.
- Charging Infrastructure
Imagine fast and accessible charging is now all figured out. Now comes another challenge, how do you make it widely available. Users expect rapid charging options to minimize downtime, but achieving this involves addressing technical barriers in both hardware and software.
For micro-mobility solutions like e-scooters, swappable batteries are emerging as a promising approach to reduce range anxiety and improve convenience. Instead of incapacitating a device for charging, a second battery comes in handy to offer possibilities for either extended range, or simply continuous use, eliminating down periods while charging.
- Weight Management
Weight directly impacts energy consumption and device performance. Engineers must strike a balance between durability, safety, and minimal weight by leveraging lightweight materials and designing highly efficient power systems.
The general rule is bigger battery size means a longer battery life. However, bigger size also means more weight, which means increased use of power reducing battery life. So, the cycle turns inefficient, and the key challenge is balancing innovations to maximize performance and efficiency. For example, compact chargers tailored for specific devices help optimize energy usage while maintaining user-friendly designs.
Challenges in Sensors
- Safety Monitoring
Sensors are indispensable for ensuring the safety of e-mobility systems. By integrating the right devices, engineers can address common challenges in e-mobility design, detecting and alerting drivers or controllers about hazardous conditions such as overheating, abnormal pressure changes, or gas leaks.
These real-time insights not only protect users but also prevent potential accidents that could damage the vehicle.
- Efficiency Optimization
When it comes to efficiency, it’s not all battery and power solutions. In fact, sensing solutions play a key role in addressing challenges, improving energy management, and extending device range. By monitoring key parameters like temperature, pressure, and electrical flow, sensors enable systems to operate within optimal ranges to maximize efficiency.
For example, advanced Battery Management Systems (BMS) use this data to optimize state-of-charge monitoring and support regenerative braking, reducing energy loss.
Challenges in Connectivity
- Data Security
Connectivity enhances e-mobility, but with it comes an added layer of challenges. Whenever we talk about integrating connectivity, we must consider data security. Safeguarding sensitive information is non-negotiable in all scenarios, as even seemingly innocuous data, such as battery consumption or location tracking, could expose users to risks if improperly secured. Engineers must design systems that ensure data integrity and protect user privacy while maintaining functionality.
- Reliability
The interconnected nature of e-mobility systems means that ensuring reliability is a must. Any failure in connectivity could disrupt critical features, from navigation to energy management. Providing consistent performance across diverse operating conditions and at all levels is a priority for the industry.
Innovation and Integration in E-Mobility
Power Innovation
A Growing demand for e-mobility comes with the need for innovative power solutions to meet user expectations for faster charging, extended range, and optimized performance. So how do we achieve these goals while addressing the technical challenges and balancing the trade-offs that come at every stage of design? Here’s an in-depth look at the current engineering strategies in play.
Faster Charging
Faster charging is becoming more and more a given expectation from users, especially in e-mobility, where charging times are a main obstacle when compared to, for example, gas powered vehicles. However, achieving this comes with inherent challenges.
One straightforward solution is increasing the power supplied to the battery, which does reduce charging time. However, this method generates excessive heat, which can degrade battery performance and accelerate wear over time.
To mitigate these issues, engineers are leveraging advanced Battery Management Systems (BMS) and thermal management techniques. BMS technology monitors and regulates charging to prevent overheating and optimize battery health.
On the other hand, innovations in battery chemistry are paving the way for solutions that can withstand the demands of fast charging without compromising efficiency or longevity.
Managing Trade-offs
So how do you balance the trade-offs? Balancing fast charging with battery health requires a multi-layer approach:
- Thermal Management
- Active liquid cooling systems effectively dissipate heat during high-speed charging, protecting the battery from degradation.
- Optimized Charging Algorithms
- Techniques like constant current, constant voltage (CCCV) charging are widely adopted. This begins with a steady current, then, as the battery nears full charge, transitions to a constant voltage phase. This controlled approach minimizes heat and extends battery life.
- Emerging solutions use dynamic charging speeds that adapt throughout the cycle, reducing stress on the battery.
- AI-Driven Optimization
- Artificial intelligence (AI) is becoming a game-changer across the industry, and this is also true in battery management. AI models analyze user behavior and environmental conditions, customizing charging profiles accordingly, achieving optimal efficiency and reducing wear.
- Advances in Battery Chemistry
- The adoption of materials like lithium iron phosphate (LFP) and solid-state batteries offers enhanced durability and better resistance to the stresses of fast charging. Solid-state batteries, for example, use solid electrolytes instead of liquid ones, providing greater thermal stability and efficiency under high charging currents.
Battery Capacity
The size and capacity of batteries introduce another set of trade-offs. Larger batteries deliver extended range but add significant weight and cost, while smaller batteries prioritize portability and efficiency. Which way to go then?
Modular battery systems are emerging as a flexible solution to this dilemma. These systems allow users to customize their battery configurations based on needs:
- For shorter trips, smaller and lighter batteries can suffice, whereas users can have a larger, heavier battery readily charged and available for longer requirements. Or…
- Swappable battery systems, as we saw earlier, ensure users can quickly replace depleted batteries, eliminating the need for a single, large-capacity unit.
Sensor Innovation
When it comes to sensors, it’s about addressing all critical applications to collect effective, real-time data that optimizes energy use, extends battery life, and ensures safety. Sensors can also play a key role in predictive maintenance, which is ideal for device longevity.
Optimizing Battery Efficiency with Current Sensors
Current sensors are indispensable for maximizing battery performance and energy efficiency. The data related to these devices and the proper management of it can directly influence range, longevity, and operational cost. Current sensors contribute to several aspects, such as:
- Battery Management Systems (BMS): These sensors monitor the flow of electricity into and out of the battery, ensuring safe charging and discharging. This prevents damage caused by overcharging or deep discharging, both of which can shorten battery life.
- State of Charge (SOC) and State of Health (SOH): These parameters track the remaining energy and overall condition of the battery, respectively. Accurate measurements enable predictive maintenance and better energy management.
- Balancing Multi-Cell Battery Packs: Current sensors help ensure even charging and discharging across individual cells, preventing overload and maximizing the energy potential of battery packs.
- Overheating Prevention: Current sensors detect excessive currents, which is often a root cause of overheating. This allows engineers to address the issue before it escalates, again acting ideally towards predictive maintenance.
Other Sensors
As we mentioned earlier: it’s about addressing all critical applications to make sure we’re gathering data effectively towards optimization. So, beyond current sensors, other sensor types such as temperature, pressure, and gas leakage sensors, are vital for maintaining both safety and performance in e-mobility. Which applications should we consider covering?
- Temperature Sensors
- Battery Management: Monitor thermal conditions to prevent overheating, which can lead to reduced efficiency, shortened lifespan, or catastrophic thermal runaway events.
- HVAC Systems: Going beyond practicality, temperature sensors can also help maintain cabin comfort while managing energy use efficiently.
- Pressure Sensors
- Battery Safety: These sensors detect pressure changes that signal potential thermal runaway in lithium-ion cells. By identifying excessive internal pressure early, they help prevent rapid discharge, outgassing, or even explosions.
- Critical Systems: Pressure sensors are also used in tire pressure monitoring for optimal driving safety and in brake systems for precise pressure control.
- Gas Leakage Sensors
- Though often overlooked, this type of sensor can greatly improve e-mobility devices. By detecting harmful gases such as hydrogen, which can leak from batteries under extreme conditions, they reduce fire hazards and improve overall safety.
- Sensor Fusion for Advanced Safety Systems
- Integrating the right sensors (e.g., temperature, pressure, gas leakage, and humidity) into a single system helps achieve a “sensor fusion.” This enhances reliability and accuracy, creating a comprehensive view of the vehicle’s condition at all times. This also creates redundancy, ensuring that no data is lost, and the right actions are triggered in a fail-safe design.
- Cost vs. Functionality
- Finally, it’s always important to consider the question of what you want vs what you need. While multi-sensor systems provide robust safety and performance, they come at a cost. Manufacturers must strategically select the most impactful sensors to balance functionality without compromising affordability.
Connectivity Innovation
Connectivity is at the heart of modern e-mobility, bringing together all elements for user convenience, performance, and operational safety. This technology plays a key role not only in intelligent features like “Find My Vehicle” and secure unlocking, but also in vital aspects like predictive maintenance. These advancements enhance e-mobility while carefully managing power consumption and security.
Making E-Mobility Smarter
Modern e-mobility devices integrate advanced connectivity technologies to offer features that redefine convenience and efficiency:
- Secure Connectivity and Data Privacy
- Connectivity features must always be accompanied by robust encryption and authentication systems to protect user data. Mutual authentication protocols ensure both the cloud, and the device validate each other, safeguarding against unauthorized access.
- AI and Predictive Intelligence
- Behavioral Analysis: AI integration can help predict user habits, such as preferred configurations, thus optimizing navigation and user experience.
- Battery Optimization: Machine learning helps adopt optimal charging practices, such as limiting charges to 80% for extended lifespan, and is key to predicting maintenance needs.
Connectivity Technologies at Work
The choice of connectivity solutions influences the functionality, security, and power consumption of e-mobility systems. When it comes to choosing the right technology, we must consider not only the applications, but how the added features may impact battery consumption and adjust accordingly.
- NFC (Near Field Communication): Best for short-range tasks like tap-based unlocking. Offers simplicity and security through proximity.
- Bluetooth Low Energy (BLE):
- Enables medium-range operations like pairing with smartphones.
- Offers enhanced security with encrypted links and intermittent data transmission for reduced power consumption.
- Wi-Fi 6/6E:
- Wi-Fi 6: Optimizes battery life with features like Target Wake Time (TWT), which schedules communication, allowing devices to remain in low-power sleep mode between transmissions.
- Wi-Fi 6E: Adds the 6 GHz band for high-bandwidth, low-latency applications like robotics, improving performance while reducing interference.
- Cellular (4G/5G):
- Provides direct cloud connectivity with secure features like SIM-based authentication.
- 5G introduces PSM (Power Saving Mode), allowing ultra-low power use during idle periods without sacrificing performance.
Layered Security for Safe Connectivity
On the side of security, each connectivity method presents unique vulnerabilities. It’s important to know them, address them, and tailor security measures:
- NFC: Relies on proximity for security but must guard against interception.
- BLE: Requires secure implementation to avoid unencrypted links.
- Wi-Fi/Cellular: Demands advanced encryption (e.g., TLS) and authentication mechanisms to protect against cyber threats.
Combining multiple technologies (e.g., BLE for local tasks and cellular for cloud communication) creates a robust, flexible, and secure system.
Lightning Board: A Case Study
The Lightning Board, developed by Future Electronics’ Future Design Center (FDC) team in London, offers an innovative answer to the challenges posed by the boom of Light Electric Vehicles (LEVs), such as e-bikes and e-scooters. Designed as a 250W AC-DC power supply reference board, the Lightning Board tackles key issues in e-mobility design, including weight, cost, and battery optimization, making it an ideal case study for advancing e-mobility technology.
In this section, Riccardo Collura guided us through the features and benefits of the board.
Efficiency and Cost-Effectiveness Without Compromise
The Lightning Board achieves an impressive 94.5% efficiency, a standout performance for its class. This is in part thanks to the use of super-junction MOSFETs, which minimize energy losses while keeping costs low. These super-junction MOSFETs offer a perfect balance between performance and affordability when compared to higher cost materials like Silicon Carbide (SiC) or Gallium Nitride (GaN), all while remaining super compact.
This board also integrates a smart charging algorithm that reduces heat generation during operation, ensuring fast battery charging without compromising safety or efficiency.
At the core of the Lightning Board is NXP’s TEA2017 combo controller, a dual-function chip that combines Power Factor Correction (PFC) and LLC (Resonant Converter) functionalities. This eliminates the need for multiple controllers, resulting in:
- Size and weight reduction: The board’s compact design reduces device weight, which is a critical factor for LEVs.
- Cost reduction: Fewer components mean lower manufacturing costs, in this case, without sacrificing reliability and performance.
Designed for the LEV Market
The Lightning Board’s design is specifically tailored for light e-mobility applications, targeting mass-market customers such as e-scooter and e-bike manufacturers who can benefit from:
- Programmable Charging Algorithms: Leveraging clever analog components and NXP microcontrollers, the board optimizes battery charging without requiring expensive dedicated controllers.
- Adjustable Output: Its constant current (6.5A) and voltage (42V) controls are easily adjustable, enabling manufacturers to adapt the board to various LEV models and use cases.
This board was designed with adaptability in mind, prioritizing flexibility for manufacturers to customize their designs without incurring additional costs.
Simplifying Challenges in Charger Design
Some of the main challenges in battery charger design that can be tackled through the Lightning Board include:
- Power Supply Expertise: The complexity of power supply design, transformer configuration, and resonant choke integration.
- Thermal Management: Ensuring devices remain cool under heavy use.
- Regulatory Compliance: Meeting EMC (Electromagnetic Compatibility) standards.
The Lightning Board addresses these obstacles with a pre-tested, ready-to-use solution that streamlines development. Rigorous testing ensures compliance with industry standards and guarantees efficient thermal performance and low radiated emissions.
Accelerating E-Mobility Innovation
By simplifying challenges and offering a comprehensive solution, the Lightning Board aims to lower the barriers to entry for LEV manufacturers. Its hardware-software synergy, compact and efficient design, and cost-effectiveness, look to foster innovation in this rapidly growing market, providing a model to design the next-generation charging solutions that will define the e-mobility revolution.
Future Trends in E-Mobility: Envisioning the Ecosystem of Tomorrow
The trend towards e-mobility is no longer a part of the future, but sits comfortably in the present now. As the trends continues to grow, we can only infer how the e-mobility ecosystems of tomorrow may look like. To get an educated guess, our panelists drew a picture from their own areas of expertise, sharing a vision and insights of how engineers can prepare for the next wave of technological innovation.
The Ideal E-Mobility Ecosystem
The future of e-mobility isn’t just about creating better vehicles—it’s about transforming the entire transportation ecosystem.
- Ubiquity of Sensors and AI at the Edge
Davide envisions a world where personal car ownership in urban areas declines and is instead replaced by autonomous vehicles available on demand.
In this future, sensors will be everywhere, integrated into all forms of mobility, from bicycles to motorbikes, and are able to track, learn and tailor experiences thanks to the incorporation of edge intelligence and embedded AI capabilities. This sensor ubiquity will not only enhance safety and functionality but will also reduce reliance on external microcontrollers.
- Interconnectivity Across the Grid
For Riccardo, the ideal ecosystem includes:
- Smart Charging Stations: These allow users to charge vehicles anywhere, anytime, with real-time data optimizing energy use, reducing congestions and waiting times.
- Bi-Directional Chargers: These chargers enable vehicles to act as energy storage units, feeding power back into the grid and supporting renewable energy efforts.
- Traffic Optimization: Real-time data sharing among vehicles and infrastructure improves traffic flow and energy efficiency.
- Sustainability as a Core Principle
Riccardo also emphasizes the importance of sustainability:
- Vehicles should be built to last at least 10 years, incorporating recyclable materials to minimize environmental impact.
- Batteries could see second-life applications, repurposed for energy storage rather than discarded, extending their usefulness and reducing waste.
- Advances in Connectivity Technology
Rabee highlights connectivity advancements like Cat-1 BIS, a low-power communication standard that offers global coverage and cost efficiency. This technology is key to enabling secure, low-energy communication within the e-mobility ecosystem.
How Engineers Can Future-Proof Their Designs
But how can we ensure devices last at least 10 years in this fast-moving world? The rapid pace of change in e-mobility demands innovative thinking and strategic planning, to which our panelists mentioned:
- Embrace Collaboration with Distributors
Davide notes that distributors like Future Electronics provide a unique advantage by offering access to supplier roadmaps and insights into emerging technologies. This collaboration helps engineers:
- Select components with long life cycles to reduce obsolescence.
- Design solutions that remain relevant for 10 years or more.
- Leverage Technical Expertise Across Domains
Riccardo points out that distributors are not merely vendors; they’re also designers. By combining expertise across sectors, distributors can recommend cutting-edge solutions for custom needs and specific applications.
- Plan for Durability and Innovation
Engineers need to balance cost and performance while preparing for future challenges. By incorporating durable components and scalable technologies, they can ensure their designs are ready to adapt to market demands and technological shifts.
Contact
Contact a designated expert at Future Electronics to get insights and roadmaps to your applications in e-mobility. Tell us about your project and find tailored solutions to bring it to life!
Looking for more insights? Visit our previous panel editions and explore expert perspectives on the trends shaping the future of the industry.
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