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The Phoenix Contact innovation magazine Mobility What drives a European metropolis? Over land, on water, on the tracks, and on foot – the mobility profile of Amsterdam The refrigerated innovation Why e-mobility will only break through once the connector is cooled
FA C T S A N D F I G U R E S 4.1 billion 150 t airline passengers Payload of the new heavy-duty 57.1 km The longest railroad tunnel in the world worldwide (2017) Big Falcon Rocket from SpaceX (Gotthard Base Tunnel, Switzerland) 75.5 million bicycles in 458.45 meters The longest ship in the world, the tanker Germany (2018) Jahre Viking (scrapped in 2010) Utrecht New York The most bicycle-friendly Largest city in America city in the world (2019) 136,500 kilometers (21.25 million inhabitants) Length of freeway network in China (2017) 1,545 bus routes Route 66 in Shanghai alone the legendary interstate Istanbul The largest highway (3945 km), opened in 1926 airport in the 110,000 kilometers world – built in Length of waterway network in China (2013) 82 kilometers just 4(!) years The length of the two-lane Panama Canal Total length of traffic jams on motorways in Germany New passenger vehicle in the years 2002 to 2018 (in kilometers) registrations (in millions) 1,750,000 Germany 1,528,000 3.51 1,448,000 Length of traffic jams in kilometers 1,500,000 1,378,000 1,250,000 1,100,000 960,000 1,000,000 China 830,000 750,000 450,000 595,000 6.7 500,000 400,000 321,000 359,000 250,000 0 2002 2006 2010 2011 2012 2013 2014 2015 2016 2017 2018 Source: Statista 2019 18% 12.5% 1.0% 2.69% of all Americans consider of Munich's transport of new vehicle registrations of global CO2 emissions the public transport system infrastructure serves as in Germany are electric is generated by air to be well developed parking space (2018) passenger vehicles (2019) transport (2015) 2 UPDATE 3/19 The Phoenix Contact innovation magazine
EDITORIAL Action, please! Dear readers, Mobility is not just something technical, useful, or fast. Mobility is also something emotional. Something that we ourselves, in the truest sense of the word, live and experience every day. Naturally, as the General Managers of Phoenix Contact E-Mobility, the subject of electric mobility is close to our hearts. After all, Phoenix Contact has been shaping the field of e-mobility with a wide range of products and technologies since 2011, with the development of the cooled High Power Charging solution currently in focus. Starting on page 28, read about how Michael Heinemann and Ralf Döhre, a single component led to the development of the complex HPC charging General Managers, Phoenix Contact E-Mobility system that is suitable for everyday use. A very special “Charging chitchat” section, starting on page 34, takes a look at day-to-day driving with electric cars and individual experiences. Phoenix Contact employees describe their experiences of mobility with a connector – and demonstrate that e-mobility has long been ready to be a part of our everyday lives. But mobility is much more than just electric mobility. Using Amsterdam as an example, we will be taking a look at what means are necessary to cope with individual mobility in the age of ever-expanding cities. The modes of transport employed in the innovative Dutch metropolis could hardly be more varied. The mobile treasure hunt begins on page 14. Incidentally, we will be revealing more about ourselves and these subjects on the blog accompanying our UPDATE innovation magazine. Among other items of interest, you will find further images, reports, and news on Phoenix Contact there. The blog can be found at update.phoenixcontact.com. The Phoenix Contact innovation magazine UPDATE 3/19 3
The Phoenix Contact in- novation magazine Mobility What drives a European metropolis? Over land, on water, on the tracks, and on foot – the mobility profile of Amsterdam The refrigerated innovation Why e-mobility will only break through once the connector is cooled The fairings of a bright red sports car represent the dynamics of mobility in all of its fascinating and challenging facets Water versus land, car versus bicycle and railroad – how does a metropolitan area find a balance? 14 LOOKING BACK FROM THE FUTURE Do you remember, back in 2019 ...? How do we explain expressions such as exhaust pipe, smog, gas station, and traffic jams to our grandchildren? | 8 Urban mobility What will the future of transportation look like in Amsterdam, the ancient metropolis of trade? | 14 4 UPDATE 3/19 The Phoenix Contact innovation magazine
PIONEERS Everyday life with electric mobility – An adventure What is behind the no more 34 plastic casing of a fast charging connector? 28 A modern approach to transit upgrades The USA – a country 42 full of contrasts: What is life like between big block and Tesla? 40 SWISSLOOP E-MOBILITY IN EVERYDAY LIFE TECHNOLOGY Swiss Charging chitchat A modern approach acceleration Electric vehicles have long since to transit upgrades What are Swiss students looking become a part of everyday life. Talking When expanding its track, a to do with SpaceX's high-speed shop at the charging station | 34 major transit agency improved tube and circular connectors the safety and efficiency from Phoenix Contact? | 24 FAST CHARGING of its communications and signaling system | 42 Charging in the fast lane HIGH POWER CHARGING The first 450 kW charging station has The future of E is HPC been opened near the A8 freeway | 38 Editorial | 3 The rapid development of fast From the industry | 6 charging technology | 28 IN DEMAND Behind the scenes | 44 Legal notice | 47 Between big block and Tesla Preview | 47 How is the home country of automobile mobility dealing with the rapid technological shift? | 40 The Phoenix Contact innovation magazine UPDATE 3/19 5
F R O M T H E I N D U S T RY Developed by Designworks: The Skai air taxi Who is ready to spring into the air? Thanks to fuel cell and drone technology, our airspace will become accessible with practically zero emissions The question above is no The start-up company Designworks has now unveiled skeptical of the idea, because longer as strange as it once Alaka'i is demonstrating just the five-seater Skai air taxi. The the noise, a lack of landing was. Following on from global how close this idea is to being technological features include space, and environmental shipping companies stating ready for series production. a six-motor drone with a fuel regulations render urban their intentions to use airspace The Massachusetts-based cell that gives it a range of up applications rather improbable. to deliver parcels, the first start- company commissioned the to 640 kilometers. ups are looking into the realistic BMW subsidiary Designworks According to a statement skai.co possibility of sending ultralight to undertake a study. Together issued by BMW itself, however, taxis into the air. with the American company, the parent company is rather Plugging in Centimeters instead of meters Electric vehicles are becoming more common on U.S. Lightning-fast reactions make autonomous driving safe roads. In the long term, this will help reduce air pollution Using the new radar sensor modules, processes. Only reaction instructions and other environmental issues, but it has led to the Berlin Fraunhofer Institute wants are sent to the actuators. infrastructure and parking challenges in American cities. to make autonomous driving much The research project is expected Fortunately, many municipalities are adopting EV-friendly policies. safer and more feasible. When a to be completed as early as The Environment America Research & Policy Center released a person driving at 50 km/h recognizes report, “Plugging In: Readying America’s Cities for the Arrival of an emergency situation, it will Electric Vehicles,” that highlights proven strategies for solving take around 1.6 seconds urban issues around EVs. A few of the recommendations include: for him to react. During • Partnering with businesses to use existing parking this time, he will have infrastructure while providing EV charging travelled more than • Encouraging sharing of e-mobility options, such 20 additional meters. as car sharing, ride sharing, and bike sharing Although the sensors used today need just • Developing apps so that EV drivers can easily find 0.5 seconds to react, available chargers and dedicated EV parking the new controllers https://environmentamericacenter.org/reports/amc/plugging developed by the Fraunhofer Institute can react up to 50 times faster. From detecting a hazard to applying the brakes, the vehicle will 2020. Testing is currently underway have travelled just 15 cm. in the dense jungle known as This is made possible through Berlin traffic, and there has been neural networks connected to considerable success in this process. radar and video sensors. The data is fed directly into a module. Only fraunhofer.com the relevant data is read out and evaluated via machine-learning 6 UPDATE 3/19 The Phoenix Contact innovation magazine
F R O M T H E I N D U S T RY Panta rhei – Everything flows Using watercourses to generate electricity In the case of the “Strom-Boje” Prinzenstein waterway close to St. power buoy, the above ancient Goar in Germany. At the average Greek quote is not meant in a speed of flow, the system power purely philosophical sense. The is approximately 65 kilowatts. The Austrian company Aqua Libre is operators of the MittelrheinStrom dedicated to the development of Middle Rhine electricity project turbines for rivers. The company's in Bingen expect to produce up launch of the Strom-Boje power to 400,000 kilowatt hours of buoy marked the introduction of a electricity per year. An enormous power generation system that will advantage of this type of draw energy from the Middle Rhine regenerative electricity generation section of the Rhine River. is that the weather and the time of Positive train control progress A total of 16 underwater day do not have any effect. turbines with an individual length of 11 meters and a weight of strom-boje.de The Federal Railroad Administration (FRA) today provided seven tons will be installed in the a quarterly status update on railroads’ progress in fully implementing positive train control (PTC) systems. Based on railroads’ Second Quarter 2019 PTC Progress Reports, which were due to FRA by July 31, 2019, the 42 railroads subject to the statutory PTC mandate are making steady progress. As of June 30, 2019, PTC systems were in operation on approximately 50,300 (87 percent) of the nearly 58,000 route miles required to be equipped by Congress. This reflects a 4% increase since Quarter 1 of 2019. Nonetheless, railroads must still complete significant work to fully implement their PTC systems by December 31, 2020, especially with respect to activating PTC systems on the remaining required main lines and achieving the necessary interoperability with their tenant railroads. https://railroads.dot.gov/newsroom/federal-railroad-administration- publishes-railroads%E2%80%99-second-quarter-2019-positive-train Surtrac allows traffic to move at the speed of technology A team of researchers and the intersection by optimizing over roboticists from Carnegie Mellon the model second-by-second. Then, University are working with the traffic signal communicates Pittsburgh city engineers to give with neighboring intersections to more Pittsburgh drivers the green coordinate traffic flow in real time. light. Finally, the system acts to control Surtrac is a real-time, intelligent the state of the traffic signals at the traffic signaling system currently intersection. in a pilot project that will improve About 15 percent of Pittsburgh traffic flow in the city. The traffic intersections have already been signal system first senses vehicles, equipped with the smart system. pedestrians, bikes, and other forms of transit to build a real-time model https://www.cmu.edu/news/stories/ of travelers and where they are archives/2019/october/traffic-moves- headed. Next, the system plans at-speed-of-technology.html how to best move travelers through Photo courtesy of Carnegie Mellon University The Phoenix Contact innovation magazine UPDATE 3/19 7
Do you r emember, back in 2019 ...? How will we judge today's developments in mobility in 20 years’ time? How will we explain terms such as traffic jams, gas pump nozzles, smog, and exhaust pipes to our grandchildren? A visionary look back at the year 2019. A nyone of a certain age surrounded by younger people today will be the most likely to notice the rapid pace at which our world is changing in terms of technology. And anybody who uses terms such as “rotary dial,” “tape recorder,” or “record player” will earn a questioning look from the youth of today. Mobility is undergoing a dramatic transformation that has really picked up pace in recent years. Where will this journey take us? How will people be trav- eling in the year 2040? In order to find out, we took a short journey through time. At least, intellectually – and with expertise. Our companion on this journey was Dirk Kunde, a journalist based in Hamburg who A knowledgeable companion in the journey through time: is right at the center of this “new mobility”: Urban, Dirk Kunde, journalist and e-mobility expert without our own car, constantly on the move, always online, connected, right through to Elon Musk. Read on to listen in on Conversation 2040 and the recollections of 2019 … à The Phoenix Contact innovation magazine UPDATE 3/19 9
LO O K I N G B A C K F R O M T H E F U T U R E è Dirk, now that it is 2040, what is life like in your home è True, they have disappeared completely from the city of Hamburg today? cityscape. Great. Just like 20 years ago, although Hamburg has grown a Today, charging is almost always inductive. Do you remember little – it now has three million inhabitants. But Hamburg is and the foul smell of diesel on your fingers after filling up? Or will always remain the Pearl of the Elbe River. wrestling with heavy electric cables? è Three million inhabitants: What effect does that have è What was all the noise about 20 years ago about whether on mobility in the city? e-mobility would really break through or not? Just as before, transportation remains one of the challenges of It's truly strange. A whole bunch of old habits had to be broken society. There are always traffic jams because people still like to back then. The car makers did not want to give up their positions. sit in their own personal environment. Parking spaces are just as Today, young people have no idea how bad the air was in the scarce as 20 years ago. Thankfully, driving is now autonomous – cities. Do you still remember the old photos taken in the big our vehicles now head off and search for a parking space alone Chinese cities, or even in Stuttgart? What was the word for it once we have climbed out. again … ah, that's it – smog. è True, that is a very radical change. People no longer è In the beginning, the e-vehicles hardly had any range need their own car … at all. … but many still have one. Nowadays, however, it is not because That's right, that was a problem at the start. But today of necessity, but for nostalgic reasons. Having said that, most of we understand transportation differently – the all-in-one us, of course, travel emission-free – thanks to car sharing and mentality has changed. Nobody does that any more – using the public transport system. just one car to drive to the baker in the morning, to drive to work daily, even to drive on holiday. Back then, people wanted è Yes, the good old treasures. Do you still have a car that to drive electric vehicles in the same way as they drove gas runs on gas or diesel? or diesel vehicles. We very quickly learned that this was not No, I haven't had one for more than 20 years. I was one of the feasible. first people to renounce their own car. And where would I find a gas station today? è Technologically, of course, a great deal has happened. Once the step was taken to produce electric motors, further development of the storage media took place. The end result Graffiti will probably still be a part of life in 2040: Public charging station in the Schanzenviertel quarter of Hamburg 10 UPDATE 3/19 The Phoenix Contact innovation magazine
2019, still innovative, 2040, old hat: Making individual mobility electric “Individual mobility is a precious asset is the light-metal solid-state batteries of today, with their enormous energy densities. in a free society.” è The Middle East was once peppered with ultrarich desert Dirk Kunde monarchies. Do you still remember the terms “petrodollars” and “oil sheikh”? Back then, we even talked about fossil fuels, as if these valuable raw materials were just used for fuel. The fixation on crude oil was one of the biggest obstacles to the further development of è The car makers had a tough time in the 20s. Many were global value chains. Electricity was considered to be an expensive very close to shutting down. raw material in those days. Thanks to our decentralized and To start with, they were “too big to fail” – but a number of intelligent power grids, this is no longer an issue – there is them failed anyway. I have just been reading some old articles plenty of electricity. that discussed the diesel scandal. Back then, it was a huge controversy, but from today's perspective, it was the kick that è But the railroad is threatened with extinction as a result. sustainable mobility needed. This opened up a gap that was That was already evident in 2019. The railroad never managed to quickly taken advantage of and filled by logistics companies modernize. Back then, the passenger trains were spectacularly such as Amazon and Alibaba, and Internet giants such as unpunctual. We were often left hanging around at the train Google and Apple, with their own vehicles, and also innovative stations. And for goods transport, the railroad was simply too start-ups such as StreetScooter, which now dominates the inflexible. With the breakthrough of hyperloop technology, the market for light commercial vehicles. railroad is just something for the nostalgic. è Dirk, please complete the key sentence of our è Speaking of hyperloop – whatever happened to discussion. Mobility is … Elon Musk? Back then, you had a few spectacular interviews … still one of the most emotive subjects of our society, but with this innovative lateral thinker. has long since freed from the stigma of not being able to unify Ah yes, Elon. He relocated to Mars in his old age when his nature and technology. Individual mobility is a precious asset company, SpaceX, was taken over by the Chinese. He had it in a free society. (lo) written into his contract that he would be among the first settlers. I heard that he has had himself frozen. www.textkunde.de The Phoenix Contact innovation magazine UPDATE 3/19 11
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Amsterdam in motion Since time immemorial, many paths have converged on the historic trading metropolis of Amsterdam. Transportation is a central theme in the Dutch capital, making it exactly the right place to get closer to the phenomenon of urban mobility. The Phoenix Contact innovation magazine UPDATE 3/19 15
URBAN MOBILITY T he metropolises of our planet are becoming And how is Phoenix Contact contributing to ever larger. The megatrend of urbanization these? We wanted to experience the answers to this marches on uninterrupted. When question first hand. Upfront and personally. One transportation becomes a problem, how will it be day. One city. As many different modes of transport feasible to transport goods and passengers? What as possible. related to Phoenix Contact. To put it problems will individuals be faced with? What are another way, a mobility treasure hunt right through the alternatives for preventing or reducing the Amsterdam, the Dutch capital. chances of traffic gridlock and pollution? #sil #safetycontroller #signallights #remotecontrol The Schinkelbrug In the middle ages, Amsterdam was the largest port in “The system is made up of a total of seven bridges, the world. Water is still shaping the cityscape today. all of which can be raised and lowered,” explains A network of canals, locks, and bridges ensures that Braam. “The subway, intercity railroad, freeway, the water-based traffic reaches the heart of the city. pedestrian paths, and cycle paths all cross over the Mischa Braam is the infrastructure industry river.” If a large ship wants to pass through, the bridge manager at Phoenix Contact Netherlands. When it elements are raised. This almost only ever happens at comes to bridges, tunnels, and locks, his knowledge night, when the traffic is lighter. “We are developing is second to none. The first stop on our tour is the the complex signal control system, which starts a Schinkelbrug bridge system, a part of the A10 orbital long way before the bridge,” Braam says. All products freeway surrounding Amsterdam. used must be SIL-certified; that is to say, they must satisfy the safety directives. Communication with the various signaling devices is carried out via cable. 1972 Year of completion 14 meters is the maximum 160 meters 7 bridges for road and navigable width total length rail transport, subway and pedestrians 16
8 lanes 1,263 2meters long pipes 200,000 vehicles per day #ventilation #proficloud #surgeprotection #tunnellighting #cameratransmission #controlengineering The Coen Tunnel Mischa Braam, Phoenix Contact NL We also drive to the next infrastructure project with our control modules. The lighting in a tunnel by car. It takes us to the Amsterdam Harbor. We is divided into different light zones, which can be approach a tunnel system between the docks and controlled such that the driver does not drive into high barriers. “Like the Schinkelbrug, the two pipes darkness and isn't blinded at the exit by the sudden of the Coen Tunnel are a part of the orbital freeway sunlight.” system surrounding Amsterdam,” explains Braam. Electronic control and communication are also “The tunnel lighting here has been equipped necessary if the signals on the crossbeams above the carriageway are to react to the flow of traffic. Furthermore, the camera units have to transmit their data to a traffic control room. “We are currently developing a solution for such applications together with our German colleagues that is easy to install and connect. Communication can then be wireless, for example, with the Radioline wireless system,” Braam says. We continue on to the city center. To the left, a canal; to the right, apartment blocks – typical Amsterdam. The waterway is called the Westerkanaal and is an extension of the Singelgracht canal. Back in à 1660, this still formed the city limits. The Coen Tunnel passes below the harbor and the Ij River The Phoenix Contact innovation magazine UPDATE 3/19 17
URBAN MOBILITY #trafficlightcontrol #radioline #controlcenter #cameratransmission The Singelgrachtbrug Even the transportation routes themselves are mobile here The lift bridge in front of us is called the is no need for long access ramps, and so the structures Singelgrachtbrug bridge, which means canal bridge, fit neatly into the cityscape, saving space. There are and is a combination of three railroad bridges. more than three times as many bridges in Amsterdam The canals are not just omnipresent here, they as there are in Venice. are also an active means of mobility. Around 200 of A disadvantage for all those who are not traveling them are shaped in a ring around the old city center. by water: They will sometimes have to wait. The signal The other modes of transport have to pass either routing system that guides such a wide range of vehicles over or under them. As is the case here, a multi- through the traffic streams while limiting their effects track railroad. What is unusual here is that many of on each other as much as possible is exciting. Data the bridges can move, either by a lifting or swiveling transmission, power supplies, control rooms, control mechanism. This is a huge advantage because there cabinets – there’s a broad field. 1,281 bridges 200canals 75 kilometer-long canal system 18 UPDATE 3/19 The Phoenix Contact innovation magazine
1977 Inauguration 295,000 passengers per day / 107.7 million per year 52.2 kilometers in total Multimedia installations help with orientation #cabling #infraredsensortechnology #passengercontrol of the history of the city of Amsterdam – as early as #datatransmission 1323, the then fledgling city gained the monopoly on importing beer from Hamburg. Nowadays, the Heineken brewery is the second-largest brewery in the world. The Metro Beer, however, is not a part of our travel plans today. We are going deep into the underground of Amsterdam. Above us, time-honored, below, ultramodern: The first parts of the Amsterdam subway were inaugurated in 1977. However, the term We continue toward the city center and visit a parking “subway” is not entirely correct – just 10.6 of the 52.2 garage. We park our car in the Heinekenplein square, kilometers are actually underground. a place steeped in history. Beer is an important part The construction costs were enormous because the solid foundation of Amsterdam first starts 18 meters below ground – above that, it is just silt and mud. The route that we are taking, line 52, was only inaugurated in July 2018. The stations are just as ultramodern as the line. The architecturally challenging solutions are typical for Amsterdam. The Vijzelgracht, which is the name of our station, gleams with multimedia installations and a sophisticated passenger navigation system. The detection of the users is important for controlling the trains. The passengers are detected and counted by infrared sensors above the automatic doors. This is an application for which Phoenix Contact provides solutions. à The Phoenix Contact innovation magazine UPDATE 3/19 19
1889 year of completion 160,000 intercity rail passengers per day 100 buses use the terminal per hour #controlbox #pushin Centraal Station #streetlighting Just two more stations, and then we leave the subway again – incidentally, at a depth of 21 meters. We have reached the heart of Amsterdam. Three artificial islands and 9,000 wooden piles were needed to create the foundations for the Amsterdam Centraal transport hub. The train station was opened in 1889. The subway passes through here directly below the antique construction. Although from the outside this looks like other old buildings, it is technologically state-of-the-art. Eurostar, ICE International, and Thalys provide the connection to the high-speed network of European intercity railways. Buses head for their own terminal inside, the IJzijde Bus Station, with a sophisticated passenger and bus stop control system. This bus terminal lies below an enormous 22-meter-high glass dome roof with a length of 360 meters and a width of 22 meters, and features a fantastic view of the Amsterdam Harbor. Incidentally, as of 2022, diesel-powered buses will no longer be permitted in the center of Amsterdam. Towering at a height of 22 meters, More than 200 streetcars move passengers along 16 routes. the bus terminal has 24 stops Most of these pass through the Centraal Station junction. The S5 alone carries more than 37,000 passengers per day. 20 UPDATE 3/19 The Phoenix Contact innovation magazine
URBAN MOBILITY #signalcontrol #motorcontrol #shippingcontrol Harbor ferries We, on the other hand, head off to the waterfront, to the Waterplein Oost terminal, where ferries are a part of urban mobility. In the midst of a crowd of bicycles and pedestrians, we board one of the floating vehicles. Carrying passengers neatly separated into Voetgangers (pedestrians) and Brumfietse (mopeds), the ferry crosses the Ij, the river on which Amsterdam is built. The ferry voyage lasts just a few minutes, and then the bow door opens and crowds of cyclists and pedestrians stream onto terra firma. We are on the lookout for charging stations for canal boats. Two-cylinder engines have been banned since 2017, and as of 2025, all combustion engines will be banned on the waterways of Amsterdam. This is a drastic step, because more than 20,000 boats use these canals. A large number of these, however, are already powered by electricity alone. In addition to inner-city shipping, Amsterdam is a major “Fietsers” or cyclists have priority everywhere cruise ship port where maritime cruise ships and river cruisers dock. à 7 ferry routes >3.8 110 5,500 million passengers canal boats houseboat residents per year 21
URBAN MOBILITY #arewenotinvolved #wewillbe #? The bikes Amsterdam is the city of bicycles. They are omnipresent throughout our tour. With around 900,000 inhabitants, the city has approximately 880,000 bicycles. Bicycles account for an unbelievable 58% share of inner-city traffic. However, our tour does not include riding bikes – participating in the “Fiets” fight for survival requires The number of e-bikes is surprisingly small. special skills. Here, the otherwise relaxed way of Clearly, the residents of Amsterdam prefer to ride dealing with each other is thrown out of the window. on their typical Dutch bikes, which are neither Simply parking is only possible on special pontoons particularly ergonomic nor light. E-bikes tend to be on the water, on which the bicycle parking spaces are used by the Dutch mainly for their weekend trips. spread over two levels. Around 11,000 new parking Meanwhile, our path has led us back to the spaces have been created at the Centraal Station in parking garage. At least here there is a small recent years. Visitors stand in amazement in front of charging station and some chic rental bikes with all the walls of steel pushbikes. electric motors. 900,000 residents in Amsterdam, owning a total of 881,000 bicycles 2 million kilometers per day travelled by cyclists in Amsterdam 6,000 bikes are fished out of the canals per year 22 UPDATE 3/19 The Phoenix Contact innovation magazine
2012 Year of foundation 40 freeway kilometers between each fast charging station #chargingstation #solar #chargingcable #HPC 21,000 vehicles charged per month (September 2018) E-mobility We are meeting Thijs van den Akker, our Dutch paneled roof can be seen from a long way off – this colleague and product manager, device connections is not a dingy backyard corner on the outskirts of the and e-mobility. We travel the next few kilometers refueling business. As Thijs drives up, three vehicles with his VW Passat hybrid set to e-mode. The Dutch are currently being charged, two of them at the 350 metropolis promotes the power of the battery and kW fast charging column. charging station – despite the fact that it is close to The name Fastned says it all – it is an the coast, it is heavily polluted. amalgamation of fast and ned (for the Netherlands). The target was to have 4,000 charging stations in Fastned relies on the technology of Phoenix the metropolitan area by the end of 2018. By 2040, Contact E-Mobility, which Thijs is proud to point the entire transportation system is to be electrified out. The vision was to have a fast charging station Thijs van den Akker, – an ambitious goal. Our next stop is one of the every 40 kilometers along the freeway network – Phoenix Contact NL Fastned fast charging stations on the Amsterdam this has already been achieved in the Netherlands. orbital freeway. The wooden structure with its solar- Mobility summary At the end of the day, our feet are sore and our heads spinning. It is impressive how determinedly Amsterdam is on the move toward the big E, and how alternative mobility concepts are integrated with each other. Although almost unnoticeable, anybody looking for Phoenix Contact products will always find them at the heart of it all. (lo) Further information on transportation in Amsterdam, on the city itself, and on solutions for mobility applications from Phoenix Contact is available at update.phoenixcontact.com The Phoenix Contact innovation magazine UPDATE 3/19 23
S W I S S LO O P The Swiss lightning bolt Through the tubes at 500 km/h – Swiss precision and Blomberg innovation are paving the way for the high-speed transportation of the future. Hanno Kappen was a member of the Swissloop Team 2018 N CIS Zurich. It is not the banking district that is in the public eye this time, however, but the campus of ETH Zurich, the Swiss Federal Institute of Technology. This is where Swissloop – an innovation project at the highly prestigious international training and research center – is based. The aim is to develop innovative technologies for fast tube transportation systems with speeds of up to 1,200 km/h, in line with the hyperloop vision of Tesla founder Elon Musk. The research on this and the modifications are carried out globally by different teams. Once a year, a major competition – the Hyperloop Pod Competition – is held at Musk's company, SpaceX, in Los Angeles, where attendees demonstrate what their vehicles can do. Of the original (approximately) 1,000 teams who entered the competition in 2018, only 18 remained. After finishing third in 2017, the Swissloop team again set their sights on claiming one of the top spots in the 2018 competition. However, a problem with the motor
The E-rocket from Switzerland uncovered controller in the vacuum tube thwarted the team's expected leap onto the podium at the last second. Hanno Kappen, still an electrical engineer student at ETH Zurich in 2018, was one of the 20 or so members of the student team that made up the 2018 development group. Acceleration like a super-sports car “The project vehicle, referred to as the pod, has to accelerate to is whoever reaches the highest maximum speed in the available the highest possible speed within a few seconds in the test tube distance – and at the same time manages not to crash at the of Musk's company, SpaceX, and come to a stop in time,” explains end of the track. The drive energy must be generated (without Kappen. The race between the driverless pods is held in the USA a combustion engine) on board the pod. The vehicle designed in a SpaceX-developed hypertube, a partially evacuated tube by Swissloop is powered with 250 kWh, supplied by batteries. that is 1.25 kilometers long and has a diameter of 1.8 meters. The propulsion is generated by one 110 kW hub motor in each The vehicles are propelled along an I-rail that is anchored into of the four wheels, which are coated with a special PU foam that the floor and that runs through the entire length of the tube. The enables high acceleration and braking forces to be transmitted. requirement profile is reminiscent of dragster races: The winner The Mujinga generates a total output of 540 PS. The goal for à The Phoenix Contact innovation magazine UPDATE 3/19 25
S W I S S LO O P the Swissloop team in 2018 was to reach a speed of around 500 the entire mechanism, which then have to be compensated for km/h. This demands an average acceleration of around 12 m/s2 – at lightning speed. The axles, suspension, and absorbers must a magnitude that is normally only achieved by super-sports cars. satisfy Formula 1 demands. The vehicle does not have steering. Directional changes have High-tech down to the last detail to be performed through minute readjustments to the individual “Teams from different disciplines have to work in very close wheel drives. Contact with the I-rail is particularly sensitive cooperation in order to be able to achieve such speeds,” Kappen because this is done using small rollers, and not only on the tells us. Experts from the fields of machine building, vehicle side, but also vertically from below. These rollers are pressed technology, and electrical engineering/electronics, as well as onto the rail by spring and absorber links, and report positional hydraulics and pneumatics, worked together on the pod. deviations to the controller via sensors. This then has to react in The entire vehicle is designed to be ultralight in construction. the millisecond range, because the tolerances for rail deviation The chassis and a wide range of other components are made of are extremely tight. Furthermore, the vertical rollers also light construction materials such as carbon fiber and aluminum. have to apply controlled pressure forces to control the vertical The weight of every component was evaluated and every trick inclination angle of the vehicle – such as during accelerating or attempted in order to save just a few grams in one part or braking. another. This approach is the only way possible to be able to keep the total weight within the range of 300 kg despite the Teamwork with the industry enormous power. “Without the support of a large number of companies, we would never have been able to complete this project,” admits E-racer at Formula 1 level Kappen. This was not only true for the large number of pod “There were particular challenges in the area of the sensor components, but also for the advice on the design and operation. technology, controllers, and actuators,” explains Kappen. Due to Only advanced technology was utilized. His group, made up of the high speeds, these components had to operate at the limits four e-technology students, was given the task of overcoming of their capabilities. At 500 km/h, even the slightest unevenness all of the challenges faced in the field of energy supply and in the rail causes considerable impact forces on the wheels and control. These included battery management, various electronic At speeds of more than 500 km/h, extremely resistant connections are needed 26 UPDATE 3/19 The Phoenix Contact innovation magazine
The 2018 pod was named Mujinga “If you get up in the morning and think the future is going to be better, it is a bright subsystems for sensors and actuators, and the development of the linkage network via which the flow of data and commands day. Otherwise, it's not.” between the controller and the numerous peripheral units had to be managed. Elon Musk Neural pathways in green “It was of great value for our e-technology group to be able to call upon Phoenix Contact, which is known worldwide for its high quality, as a partner for the electrical networking,” says through its local Swiss branch,” says Kappen, summarizing his Kappen. Furthermore, Phoenix Contact also engaged in intensive experiences. Today, he lives and works in Los Angeles. consulting and support. “From this, it became apparent that the Naturally, the team from the Swiss Federal Institute of M12 circular connector was best suited for our application.” The Technology in Zurich does not want to give in after the team members were able to assemble the multiposition cables ignominy of the technical knockout of 2018 and has long since themselves where needed. For this, Phoenix Contact promptly been working on improvements and the next attempt. There is delivered the suitable cable material. Due to the green end caps, also a deeper aim, because as a land of tunnels, Switzerland is these “neural pathways” are clear to see, in particular in the planning its own version of the evacuated high-speed tube and central network controller PCB developed by Kappen, which has will need suitable vehicles. a total of 20 multiposition communication connections. “I was particularly impressed at how the company was able to provide Klaus Vollrath, freelance technology and science journalist fast, nonbureaucratic, and above all, very professional assistance The Phoenix Contact innovation magazine UPDATE 3/19 27
The future of E is HPC E-mobility is old hat. Even the oldest motorized vehicle had an electric motor. The problem back then was the same as today: How do I store as much energy in the mobile energy storage system as possible, as quickly as possible? A good 140 years later, we have come a long way. 28 UPDATE 3/19 The Phoenix Contact innovation magazine
HIGH POWER CHARGING 29
HIGH POWER CHARGING A s far back as 1881, the French inventor Gustave Trouvé However, the calls for faster charging times for cars very unveiled his sensational tricycle. Similar in appearance quickly became louder. Phoenix Contact was involved in some of to a stagecoach, it could travel at 12 km/h. With a range the first preliminary developments in this field. One of those who of about 14 kilometers, the vehicle was pretty much suitable for has been there practically from the beginning is the developer everyday use because at that time horses were the only other Dirk Moseke, who describes the steps that followed: competition for longer journeys. Werner Siemens, Andreas Flocken, Ferdinand Porsche – the Warm, yes; hot, no list of e-pioneers is long and includes some astonishing names. “Even the requirement specifications and standards were under Between 1896 and 1939, there were 565 different electric vehicle development. There simply weren't any. And that was only two brands in the world. In New York, the e-vehicle share of the years ago! And so we had to develop them ourselves. What do we market was 50% in 1901 (the rest were steam-powered vehicles have to do to develop something completely different from the or naphtha-, acetylene-, or pneumatic-driven vehicles). Even existing CCS standard with the defined mating face? 200 amps Henry Ford developed a Ford Model T with an electric motor, were not a problem, but then 300 amps and more were being although it was never put into series production. called for. Today, we are up to 500 amps. In buildings, a yellow What followed was almost 100 years of the e-mobility version sign would be placed in front of the access point to these high of Sleeping Beauty. currents with the warning ‘Access forbidden.’ And yet here we were, attempting to make these systems freely accessible on the The reawakening of electric mobility market, where they would be subject to the weather and possible It was not until 2010 that the subject picked up speed again. mishandling. At Phoenix Contact, it was initially just about individual “The starting point was the development of suitable cables. components. Early on in the revival, there were applications With such currents, there were only two options: larger cable such as heavy-duty connectors for battery packs that are still in cross-sections or significant warming. The cable couldn't be too use on Chinese buses. thick, however, because otherwise it would be too heavy and stiff. And so, we committed ourselves to the issue of heat buildup. Dirk Moseke is one of the developers of the Phoenix Contact High Power Charging system 30 UPDATE 3/19 The Phoenix Contact innovation magazine
Enabling fast charging – the cooled HPC connector A visit to the E-Mobility production facility in Schieder “In buildings, currents this high are normally hidden behind a door marked ‘Access forbidden.’ ” Dirk Moseke on handling HPC currents “In the meantime, we also realized that it is a good idea to make the surface area as large as possible. The greater the surface area, the better the heat dissipation. We therefore performed First, we had to determine exactly where the heat was being trials with large numbers of individual litz wires. At times our generated. It is in fact the cable itself that heats up. The heat work resembled a braiding shop, with shrink sleeves, cable ties, can, however, also come from the vehicle – that is to say, from a and tape all over the place. This was basic bare-knuckle research point over which we have no control. The next idea was to use that you will also find at every higher education institute. Today, fluids for cooling – that is to say, to bathe the copper directly in we have a cable that carries two sets of two 25mm2 copper a heat-dissipating medium. We discarded an oil-based solution conductors: Two for positive, two for negative. This ensures that because the handling was far too complex – and anything but the cable is not too heavy and that it is flexible. innovative. “We have incorporated a layer into the outer sheath that shows when the cable is worn or damaged. Furthermore, because Research in the braiding shop the cable can be touched, the standard states that it may not “We then tried it with air. To do this, we blew air into hoses become hotter than 60 °C. This is monitored via sensors and is in which the hot cables were laid. The air, however, has to go coupled with a disconnect unit. Communication wires also run somewhere, and it escaped through the connector. Furthermore, through the cable because the connector and station need to air doesn't dissipate the heat very quickly at all. It's impractical. communicate. We therefore continued researching alternative coolants and “The next challenge was the connector itself. Initially, it finally came up with the easy-to-handle and environmentally was stated that we even had to cool the vehicle inlet via the friendly glycol. In addition, we incorporated thermal grease into cable. This is not possible, however. That would be like opening the cable. That was quite successful in part, but was not suitable the fridge door to cool a bottle of beer that is standing on the for series production. windowsill. à The Phoenix Contact innovation magazine UPDATE 3/19 31
HIGH POWER CHARGING The most innovative system in the world “We have developed a heatsink that initially consisted of a turned copper pipe with a sheath molded around it and that was connected to the hoses. This was successful, but again, it was too complex in its construction. Today, we have a heatsink that is 3D-printed in series production that encloses an insulating body. We can thus provide cooling right through into the contacts. “All of the sealing points had to be perfect in readiness for the prototype tests – 13 or 14 sealing points, in part made of sensitive material compositions, and equipped with leakage sensors. We tested various materials in our in-house test laboratory, in particular for their conductivity. Naturally, no manufacturers share this information. This took a great deal of effort. “We carried out this development in cooperation with our colleagues from Protiq, another Phoenix Contact subsidiary. Today, we measure and monitor the temperature at the hottest points of transmission, right at the tips of the contacts. With this approach, we are protecting our entire system from external Basic material in influences; for example from the vehicle side. Currently, this is connector production the most innovative system in the entire e-mobility industry. We have patented the real-time temperature measurement system. Contact carrier with excellent thermal conductivity properties also acts as a heatsink Ergonomic handle Replaceable mating ensures easy handling face enables inexpensive Microprocessor and maintenance sensor technology and repairs transmit analysis data in real time Leakage sensor signalizes any coolant leaks Integrated temperature sensors measure the development of heat in real time Environmentally sound low-maintenance coolant dissipates the heat and prevents overheating High Power Charging Technology Designed by PHOENIX CONTACT Indicator in the cable sheathing warns of cable breaks 32 UPDATE 3/19 The Phoenix Contact innovation magazine
Production demands a great deal of specialist expertise Challenge: Series production – Dirk Moseke works closely with production 500 amps of charging power is considered sufficient for the medium-term future asking about the price. This gave us an insight into how Elon Musk must have felt while he was collecting blank-check orders for his Tesla cars. “There is a locking system that prevents the vehicle from starting during charging. If the connector is dropped and Development without end damaged, it does not have to be completely replaced. We have “Our HPC connectors went into series production at the end designed the mating face frame to be replaceable, ensuring that of 2018. At the same time, we started working on solutions for maintenance is inexpensive and flexible. the international markets – some of which have completely different standards in force. Feeling like Elon Musk “In terms of power, 500 amps is sufficient for the medium- “The next step, in cooperation with our tool shop, was the term future. But, naturally, we are continuously working on development of the pre-series tools. In part, we drew upon optimizations. After all, it is more than simply just a connector. technologies that were completely new to us, such as ultrasonic There is so much intelligence integrated into the system that welding of the copper cables to the contacts and casting the DC using it is completely safe. Furthermore, we are in constant contact area. dialog with the charging station manufacturers on subjects “Establishing this production of the highly complex such as remote maintenance and charging cable management. components is, as before, a challenge, because growth continues We are not short of things to do.” (lo) to be turbulent. In pre-series, it took two days to produce a connector – like it would in a workshop. We have since entered into series production. “Just how dynamic the development of e-mobility has become became apparent once we presented our first samples in early 2018. Some of our customers placed orders without even The Phoenix Contact innovation magazine UPDATE 3/19 33
E-M O B I L I T Y I N E V E RY D AY L I F E Charging chitchat Is it time for you to make the move to electric mobility? A number of Phoenix Contact employees have already taken the step and invested in EVs or plug-in hybrid vehicles. We recently invited drivers to chat about the pitfalls and joys of e-mobility in everyday life. Ben Bomgardner 2014 Chevy Spark EV Ben has been driving his Spark since May 2015 and was one of the first American Phoenix Contact employees to move to a fully electric vehicle. While his family still has a traditional van for driving with the kids and on long trips, he says his next car will “absolutely” be an electric vehicle. “They are much simpler than gasoline cars and extremely easy to maintain….There are no performance trade-offs for this ease of ownership, and the routine of daily charging is much friendlier than standing at the pump,” Ben said. Lonnie Swarr 2014 Ford Fusion Plug-in Hybrid Lonnie saw his vehicle at a local dealer near his house. “I liked the look, it was affordable, and it was appealing to take advantage of the plug-in charging stations at work provide by Phoenix Contact,” Lonnie said. He said he enjoys the savings at the pump. “Instead of filling up one time a week, I know only fill up one time every two weeks, and for $20 to $30 less than what it cost to fill the tank of my previous SUV…I’ve been happy with what I own now, so I would consider buying a hybrid the next time around.” Ben Bomgardner 34 UPDATE 3/19 The Phoenix Contact innovation magazine
Dave Skelton Tesla Model S 70D Dave took a test drive in 2015, he was sold. “Once you feel the instant torque available, it’s not hard to immediately want to drive this every day. Following this, researched range, cost of ownership, and reliability. On paper it all looked very good; in practice, it was even better than originally anticipated. “The most frequent question I am asked is how far you can go and where do you charge. My car is able to travel about 240 miles on a single charge. Normal charging is done either here at work or at home… This car has been on frequent trips from Florida to New Hampshire. The Tesla Super Charger Network is convenient to major routes…Today, the car navigates to the chargrs along the route, so I don’t really need to think about it.” Dave Skelton Tom Olsen Tesla Model 3 Performance Tom purchased his Tesla in March 2019. He likes that the Tesla is one of the fastest cars on the road, “certainly in my price range.” The touch screen took some getting used to, but he anticipated this. He stated, “I like having all of the ‘old-fashioned’ controls in front of me. I enjoy the process of driving and have always had a stick shift. Again, I knew that giving that up was a trade-off. Electric cars are a no-brainer for commuters. However, long trips require more planning, as you can’t fill up on every street corner. In my case, I have to allow a half hour of charging every 200 miles. I do a lot of weekend trips and have driven 25,000 miles in six months. I maintain a list of charging stations between home and my destination.” Ed Panyard 2013 Ford Fusion Hybrid Ed, who works in Ann Arbor, Michigan, bought his Ford Fusion in January 2013. He chose a hybrid because “I normally drive around 750 miles a week. The cost of gas was getting outrageous.” Like others, he cited the low cost of maintenance as one of the key benefits of his car. “I have 167,000 miles on the vehicle and have not had to replace the front brakes, and the rear brakes only once. No other major repairs.” While he would opt for an all-electric vehicle, “the distances I drive are Tom Olsen not covered on one charge, even with the longest-range Tesla. I usually hold onto my cars for ten years. By the next time I buy, I suspect all vehicles will have some hybrid technology in them.” The Phoenix Contact innovation magazine UPDATE 3/19 35
Kevin Zak 2018 BMWQ 530E (plug-in hybrid) Kevin has been driving his hybrid for about a year. “I desired to move toward an electric car initially for the gas mileage improvement, as well as the performance features. I decided to go halfway and purchased a hybrid based on my assessment that the charging infrastructure is not ‘ready for prime time.’ Since I only live ten miles from work, I charge at home during the evening and at the office during the day, making my commute fully electric. Lastly, I have a sense of pride in that – albeit in a small way – I am becoming more energy-efficient and thoughtful toward our planet,” Kevin said. “Since my purchase, I have averaged over 55 miles per gallon. During period when I am not traveling on long trips, I can go upwards of five weeks on a tank of gas (12 gallons) and average well over 70 MPG. I also truly enjoy not having the engine noise when in electric mode, as it brings a bit of Zen to rush hour traffic.” Kevin states, “I would love for my next vehicle to be all- electric, but that will depend on the EV charging station infrastructure improvements that occur between now and 2022, when I will likely buy my car.” Dan Fenton Kevin Zak Dan Fenton Tesla Model 3, Long-range, rear wheel drive option Dan is another relative newcomer to the EV world, purchasing his Tesla in April 2019. His primary reason for selecting an EV was “concern over climate change and a desire to do my part. My wife still drives a 2012 Ford Escape, but she’s pretty enamored with the Tesla. I don’t think her next car will be an ICE.” He enjoys driving his car for several reason. He says, “Honestly, though, the big one that stands out for me seems so small and silly, but there’s no feeling like waking up and knowing your car has a full, uh, ‘tank’. Sure, it’s five to ten minutes for most people, but it’s one less decision that I need to find time for on a weekly basis, and I value that. And it extends to maintenance in general, too. There’s no oil changes, the brakes have a much longer lifespan because the regenerative braking handles most of my decelerating (I drive with one pedal most of the time), and a lot of the other things that would put your car into the garage for a night or two just don’t exist. All I need to do routinely is rotate the tires.” 36 UPDATE 3/19 The Phoenix Contact innovation magazine
E-M O B I L I T Y I N E V E RY D AY L I F E Kyle Gingrich 2019 Tesla Model 3 Kyle purchased his Tesla in March, and it already has 20,000 miles garage and plug it in. There is no need to stop and get gas when it on it. He said, “I was in the market for a new car and wanted a is cold outside, snowing, or raining. I also enjoy the fact that I pay vehicle that could last me 150K+ miles. Diesel vehicles were my about 75 percent less for fuel compared to my previous car (about go-to vehicle for reliability in the past, but after the VW emissions $175 a month). Lastly, minimal maintenance saves me about $50 a scandal, it wasn’t an option anymore. The new battery technology month with my driving habits.” and moving parts have shown real-world life expectancy of 500K Like many other EV drivers, Kyle plans to purchase another in miles for a Tesla. the future. “After having my Tesla for just once month, I don’t know “I love the instant torque and no shift points from a that I could ever go back to an internal combustion engine.” transmission. I also really enjoy the fact that I can just pull in my Ron Gaudelli Dual Motor Tesla Model 3 Ron has been driving the long-range version of the Tesla (310 miles of range and a 75 KWh battery) since April of this year, but he previously drove a Ford Fusion Energy (a plug-in hybrid) for five years. “As a curiosity and in the face of increasing gas prices, I started researching hybrid and electric vehicles more than 10 years ago. Early-model hybrids were definitely more fuel-efficient than their ICE counterparts, but overpriced and somewhat uninspiring,” Ron said. “The Ford Fusion Energi, a full-sized, well-featured car with a 7.6 KWh battery, good for about 20 all- electric miles, and a 141 HP gasoline engine serving as part of a hybrid system was a great combination of local electric Ron Gaudelli driving economy and long-range and fuel-efficient hybrid travel. At the time, Tesla’s Model 3 was still not available for sale. When the Model 3 as a “truly software-driven hardware, which is it finally rolled out, I patiently observed its reviews, issues, continually being optimized, enhanced, and expanded with the development, and pricing. I was definitely interested but hesitant new capabilities. Multiple times a year, a new software is pushed. to make the switch to all electric.” It’s like getting a brand-new car many times over. A trip to Germany helped convince him to make that move. “While it is still fundamentally a means of transportation, “Ironically, one of the key decision points for me came when I driving an EV on a regular basis requires a different mindset. was in Stuttgart on a business trip. The taxi I wound up taking There are differences in driver interface, acceleration profiles, from the train station to the hotel was a Tesla Model S. I sat up braking, maintenance, car noise (or lack thereof), other drivers’ front asking the driver countless questions about the car and his attitudes (at least for now) toward an electric car, and of course, experiences with it. He was more than happy to share all he knew charging and travel planning. None of these are difficult to adapt and demonstrate everything the car could do. I was sold.” to, but they are different and must be understood to ensure a safe Ron loves two things about his car, including the “instantly and enjoyable ride,” Ron said. available, silent, ridiculous acceleration.” He also describes The Phoenix Contact innovation magazine UPDATE 3/19 37
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