Q&A With Kemarol Ibrahim: EV Design & Testing Solutions

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Following IAA’s first EV webinar titled, “EV Technology And Design Solution: Rethinking Design Approach, Connectivity, And Safety,” Kemarol Ibrahim answers the community’s EV Design & Testing Solutions questions.

Featured SPARK:

Kemarol Ibrahim, Manager, Technical & Business Development at Hexagon Manufacturing Intelligence.

About Kemarol Ibrahim:

Md Kemarol Ibrahim is currently the Technical and Business Development Manager, for MSC Software Singapore, covering the ASEAN region. Over the past decade, Kemarol has engaged with a variety of customers in ASEAN and ANZ, mainly in the Automotive and Machinery industries, where he has helped customers to set up processes based on the best practices and experiences from MSC global teams. Thanks to his previous stint at MSC Japan and his studies there, he handles the technical and business requirements of all Japanese OEMs and Suppliers in the region. M. Kemarol holds Bachelors and Masters degrees in Mechanical Engineering from Waseda University, Tokyo, Japan. His experiences and expertise cover Multibody Dynamics analysis and Nonlinear analysis.

Dom Spooner asked:

What role does design for disassembly have when considering second life cells, serviceability and maintenance, and recycling?

Kemarol Ibrahim (KI): Design for Disassembly (DFD) helps to reuse the useful and valuable materials from battery, such as metal, or lithium itself, or any useful cables. It also helps to prevent hazardous material to be dumped and cause accident. DFD has to come with manuals and workflow, so it can be done not only by original manufacturers but service provider as well. Manual helps to prevent accident as battery might still have charges and high voltage cells are quite dangerous.

Digvijay Kadam asked:

When battery validity gets over then there is only option to replace or we can reuse same battery by doing some maintenance?

KI: I believe manufacturers are considering make useful usage of old battery. There will be way of doing it, and it may open up business opportunity to disassemble, recycle or upcycle the old battery.

Sumedh Shingade asked:

Can you tell me something about electric vehicle thermal management?

KI: In operation, EV batteries generate heat, and depending on the size, the heat generated will be faster. Heat reduces battery performance, reduces battery life, and is potentially dangerous such as explosion if not properly managed. High temperature is detected by means of sensors, and appropriate heat management such as dissipating through convection by airflow, dielectric oil, or water-based coolant.

Yanzhuo Zhang asked:

What is the potential possibility of mass production for EV using metal additive manufacturing (AM) technology?

KI: There are at least four ways that AM can contribute to building EVs.

First, lighter parts help extend battery life.

Lightweighting is one way to increase battery efficiency. AM ability to produce complex but extremely optimize parts by means of 3D printing process.

Second, AM offers engineers the ability to produce parts that normally been produced separately and assembled together, into a single 3D printed parts that can be physically stronger and lightweight.

Third, materials combination is possible in AM process, that can make pars to be lighter and cost-optimized. A detail location or zone of each component can be mixed with both less strong or compose it with stronger materials by means of 3D printing process.

The only challenge now is that 3D printing process is time-consuming. If this can be overcome with mass-production and increase printing speed, it will be competitive to normal subtraction manufacturing process.

Siti Atirah Hussin asked:

How does EV save the environment and help to tackle climate change especially in Malaysia?

KI: Multiple reports confirm that Electric Vehicles (EVs) are already cleaner than internal combustion engine vehicles in 95 percent of the world and getting cleaner in terms of lifetime global warming emissions. In Malaysia, EV adoption is seen as a way to reduce carbon emissions. The government’s initiative to tackle climate change issues under Budget 2022 by introducing tax exemptions on electric vehicles could attract the public to use these vehicles in efforts to reduce greenhouse gas emissions. In his Budget 2022 speech, Finance Minister Datuk Seri Tengku Zafrul Tengku Abdul Aziz said the government will exempt import duties, excise duty, and sales tax for electric vehicles (EV) in efforts to achieve carbon neutrality by 2050.

“The government sees the potential of EVs that have the characteristics of energy-efficient vehicles as an effort to minimise vehicle smoke pollution”, Tengku Zafrul said on Friday (Oct 29).

How to connect with design thinking for innovation?

KI: To answer this briefly, design thinking consists of 5phase, and simulation helps in the 4th and 5th phase which is prototype and test.

In this phase 4 and phase 5, I would call simulation part as sub-phases of these two phases, that helps to create virtual prototype and virtual testing.

This helps in the iteration of design thinking process itself, which requires iteration of the design thinking cycle.

Rajesh Kumar Panda asked:

Are there any development going on for Na ion batteries to replace Li ion or lead acid battery?

KI: Yes there are various researches, and papers published with regards to Sodium Ion battery. It is promising with challenges meant to be solved.

Rajesh Kumar Panda asked:

How we will ensure the properties and characteristics in case of additive manufacturing?

KI: I’m not sure the question is for end product of AM or before the printing.

For End Product, we can use CT scan to scan if there is any porosity that can be deemed as defect.

If it is before the printing, then the focus is on the material to be used, either using the data as published by material supplier, or performing your own test on printed part, by printing it as coupon test. Various test scenario that depends on printing direction are proposed by researchers.

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