Tula figured out that sending pulses of electricity to an electric motor makes it operate more efficiently than a continuous flow. All it takes is 100K of code. Automakers can use the efficiency to extend the range of their EVs, or use a slightly smaller battery to cut cost. Scott Bailey, CEO and John Fuerst, Senior VP Engineering, get into the details of how the system works.
Summary of interview:
In this conversation, John McElroy interviews Scott Bailey and John Fuerst from Tula Technology, focusing on their innovative Dynamic Motor Drive (DMD) system for electric vehicles (EVs). The discussion highlights the key aspects and potential impact of this technology in the automotive industry.
Overview of Dynamic Motor Drive (DMD)
1. Technology Description:
DMD is an advanced control system for electric motors that optimizes energy efficiency by pulsing electricity rather than providing a continuous flow. Scott Bailey explains that, instead of a steady state, the system pulses the motor at higher torques where losses are lower, leading to significant energy savings. This is because electric motor efficiency improves at higher torques, and by pulsing at these higher efficiencies, overall energy consumption is reduced.
2. Operational Mechanism:
DMD works by overlaying an additional algorithm on the vehicle’s existing pulse-width modulation (PWM) system. This algorithm introduces a lower frequency pulsing strategy to the motor’s operation. The system efficiently manages the pulses to ensure minimal energy waste and maintain vehicle performance without noticeable differences to the driver.
Tula’s Track Record and Technology Integration
3. Previous Innovations:
Tula has a successful history with their Dynamic Skip Fire (DSF) technology, used by General Motors (GM) in their V8 engines. DSF optimizes internal combustion engines by selectively firing cylinders based on demand, improving efficiency and reducing emissions. This experience underscores Tula’s capability in developing effective efficiency-improving technologies.
4. Connection to Electric Motors:
Drawing from their success with DSF, Tula adapted their control philosophy to electric motors. The goal with DMD is to run electric motors more frequently at optimal efficiency, similar to how DSF operates internal combustion engines. This adaptation aims to achieve similar benefits in electric motor performance.
Efficiency Improvements and Industry Impact
5. Efficiency Gains:
DMD provides a range of efficiency improvements, generally between 0.3% and 2% depending on the driving cycle. This improvement is significant when considering the large scale of battery costs in EVs. For example, a 2% improvement can lead to savings of $160 to $240 per vehicle, either reducing battery size or enhancing vehicle range.
6. Cost-Effectiveness:
Tula positions DMD as a cost-effective alternative to other efficiency technologies like Silicon Carbide (SiC) systems. DMD’s software-based approach is significantly cheaper to implement compared to hardware solutions like SiC, which are expensive and complex. DMD’s efficiency benefit comes at about a third of the cost of SiC solutions, making it a compelling choice for automakers.
7. Scalability and Integration:
DMD is designed to be easily integrated into existing vehicle systems. It requires minimal additional computing power—less than 100 kilobytes of memory and around 2% of computing capacity—making it feasible to incorporate into current EV platforms without substantial hardware changes. The technology is also scalable, allowing for easier adaptation across various vehicle models once the initial integration is completed.
Market Adoption and Future Prospects
8. Market Reaction and Deployment:
Tula has showcased DMD to automakers worldwide and anticipates its first production deployment in China later this year. The company is also working with suppliers and automakers in Europe and the US, adapting its strategy to different market requirements. The flexibility and ease of integration are expected to facilitate quicker adoption.
9. Environmental and Cost Benefits:
Beyond cost savings, DMD’s impact on reducing the need for rare earth materials in electric motors aligns with broader environmental and geopolitical goals. By offering a viable alternative to permanent magnet motors, which rely on costly and environmentally problematic rare earth elements, DMD supports both cost reduction and sustainable practices.
10. Industry Implications:
The technology’s potential to enhance efficiency in both pure battery electric vehicles (BEVs) and plug-in hybrids highlights its versatility. Automakers could benefit from the improved energy efficiency without incurring the high costs associated with other solutions like SiC. DMD’s ability to fit into various EV architectures makes it an attractive option for future vehicle development.
Conclusion
The conversation emphasizes Tula’s Dynamic Motor Drive (DMD) as a promising advancement in electric vehicle technology, offering substantial efficiency improvements at a lower cost compared to current alternatives. With its easy integration, cost-effectiveness, and potential environmental benefits, DMD stands out as a significant innovation poised to impact the automotive industry positively.
