New automotive industry solutions

TWO SOLUTIONS for the automotive industry in the field of electroactive polymers (EAPs) and integrated electronics are offered from Datwyler. A new-principle EAP actuator saves energy, while eliminating noise and rattle in the system, while electronics embedded within smart sealing solutions enable predictive maintenance and enhance traceability.

The stacked EAP actuator is touted as a significant breakthrough in the field of electroactive polymers.

Working in collaboration with specialist partner CTSystems – responsible for the design and engineering elements – Datwyler’s says its role to industrialise and commercialize the solution has been pivotal. Engineered without the use of traditional mechanical and coil components, the actuator’s design allows it to operate in a noiseless manner that is not only more reliable but also considerably more energy efficient than conventional alternatives.

“This technology is based on the creation of small capacitors in a three-layer system, consisting of two electrodes constructed using conductive materials and a soft electroactive polymer between them. When voltage is applied to the capacitor the surface electrodes start to move towards each other, which compresses the polymer and thus allows for a small amount of axial movement. These are then created as a stack in order to facilitate additional axial movement, which when voltage is applied means the actuator can be integrated directly into virtually any component that requires actuation without the need for an additional motor or gear,” says Norbert Haberland, Head of Business Development and Cooperation for Advanced Technologies at Datwyler.

The movement or travel of the actuator can also be adjusted and controlled in a stepless manner, and as it has no mechanical elements is completely noise free, removing mechanical vibrations that can be disturbing to the driver completely. This is of particular benefit within battery electric (BEV) and hybrid vehicles, where the baseline noise created by a standard internal combustion engine (ICE) is not present to mask any additional mechanical noises. The removal of the mechanical element also increases reliability through the elimination of traditional moving parts.

“The energy consumption is also significantly lower when compared to a conventional coil system, because in a coil system you need permanent current or voltage to maintain a certain status, i.e. off or on. In the EAP system, the voltage is stored in the electrodes, and voltage is only required if a change in status from off to on or vice versa is necessary.”

INTEGRATED ELECTRONICS

The second area of focus is intelligent, integrated electronics – which can be embedded within a rubber component or, in the case of what Datwyler refers to as technical rubber, printed directly upon the surface to form a functional structure. The resulting smart sealing solutions deliver a wide range of benefits.

If we take an embedded RFID chip as an example, information can be stored that can deliver distinct benefits to manufacturers in the mobility sector. The authenticity of a part can be checked with ease, for example, while part numbers and production dates can also help to provide traceability as supply chains become ever more digitalized. Materials that are visually similar, such as membranes, can also be checked to ensure the correct materials are used when parts are assembled.

“Advances in smart sealing solutions extend far beyond the supply chain also. Sensor active layers within elastomer components can detect force, touch or even leakage, for example, and in some instances can detect the presence of media on the surface of the seal, leading to higher levels of capability in terms of predictive maintenance. As we move forward and electrification continues to gather momentum, to have these capabilities within battery packs, where any form of leakage can lead to reduced functionality or even overheating, is highly desirable,” states Haberland.

Electronic components such as chips and sensors can also detect parameters such as temperature, pressure, fluid levels and abrasion when integrated into sealing solutions. This information further adds to a vehicle’s capability to provide predictive analytics, which in turn can mitigate the risk of unscheduled downtime events and even potential safety issues.

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