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    Military Electric Vehicles -Where, Why, What Next?By Dr Peter HarropIDTechEx

    [email protected]

    www.IDTechEx.com

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    IDTechEx Ltd 2011US Tel: +1 617 577 7890

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    Contents Page

    1. INTRODUCTION 6

    2. WHY HAVE THEM? 9

    3. MARINE MILITARY VEHICLES 14

    4. MILITARY AIRCRAFT 16

    5. KEY ENABLING TECHNOLOGIES 20

    5.1. Introduction to the six key enabling technologies 20

    5.2. Traction batteries 21

    5.3. Traction motors 22

    5.4. Electronics/electrics 23

    5.5. Range extenders 24

    5.6. Fuel cells 25

    6. IDTECHEX ELECTRIC VEHICLES REPORTS 31

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    IDTechEx Ltd 2011US Tel: +1 617 577 7890

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    Tables PageTable 5.1 First major use of new electric vehicle technologies 20

    Table 6.1 IDTechEx Electric Vehicles Reports 31

    Figures Page

    Fig. 1.1 Pure electric truck for general use that is also used by the military 6

    Fig. 1.2 Small pure electric vehicle used by the US military 7

    Fig. 1.3 Polaris Industries Neighborhood Electric Vehicles (NEV)s used by the US Military 7

    Fig. 1.4 Polaris Industries All Terrain Vehicle ATV specifically designed for military use 8

    Fig. 2.1 Electric stealth vehicle 9

    Fig. 2.2 General Dynamics Land Systems Shadow hybrid electric vehicle 9

    Fig. 2.3 Millenworks light hybrid vehicle 10

    Fig. 2.4 Hybrid Future Tactical Truck System (HFTTS) 11

    Fig. 2.5 Oshkosh hybrid military Heavy Expanded Mobility Tactical Truck (HEMTT) 11

    Fig. 2.6 100mpg(US) Hybrid Hummer 12

    Fig. 2.7 Bronco hybrid from Singapore 12

    Fig. 2.8 Roboterwerk robot electric surveillance vehicle 13

    Fig. 2.9 Green Wheel jeep style pure electric vehicle 13

    Fig. 3.1 Swimmer type of AUV 14

    Fig. 3.2 Hypersub submersible fast powerboat 15

    Fig. 4.1 Boeing/ WheelTug electrified nosewheel uses Auxiliary Power Unit APU in large

    aircraft whereas the EADS version uses a fuel cell. 16

    Fig. 4.2 AeroVironment Raven, the best-selling hand launched surveillance aircraft 17

    Fig. 4.3 Aqua Puma 18

    Fig. 4.4 Very small UAVs for surveillance etc 19

    Fig. 5.1 Third generation lithium-ion battery, the lithium sulphur small UAV battery of SionPower 21

    Fig. 5.2 CERV 23

    Fig. 5.3 TARDEC APD with in-wheel motors 23

    Fig. 5.4 Evolution of range extenders 25

    Fig. 5.5 Fuel cell AUV in Japan 26

    Fig. 5.6 New and improved supercapacitors and their variants such as supercabatteries are

    becoming more and more useful in EVs 27

    Fig. 5.7 The $517 million unmanned surveillance airship currently being made for the US

    Department of Defense by Northrop Grumman showing flexible photovoltaics. 28

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    Fig. 5.8 Glider type of AUV surfacing to recharge batteries using wave power (by hinging)

    and solar power (by photovoltaics) 29

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    1. Introduction

    This white paper provides an introduction to military and allied electric vehicles and a pointer to

    the best sources of further information. It shares some of the information in the IDTechEx report,

    Electric Vehicles for Military, Police and Security 2011-2021. Military electric vehicles vary from

    those that are not designed primarily for such purposes - such as most Airport Ground Support

    Equipment GSE - and those that are. The general situation with electric vehicles of all types can

    be seen in the IDTechEx report, Electric Vehicles 2012-2022.

    Fig. 1.1 Pure electric truck for general use that is also used by the military

    Source Balqon

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    Fig. 1.2 Small pure electric vehicle used by the US military

    Source Columbia ParCar

    Fig. 1.3 Polaris Industries Neighborhood Electric Vehicles (NEV)s used by the US Military

    Source Polaris Industries

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    Fig. 1.4 Polaris Industries All Terrain Vehicle ATV specifically designed for military use

    Source Polaris Industries

    What is an EV?

    The term electric vehicle EV is limited to free running vehicles by land sea and air, so it does not

    include tethered Remotely Operated Vehicles (ROVs) under the sea that are often used by

    military forces. It does not include vehicles lacking a large traction battery or similar power

    source on board so we are not including large diesel electric and nuclear electric submarines and

    ships for example. Yet what remains is already a fast growing $53 billion business at ex-factoryprices.

    Electric vehicles can be pure electric with only an electric power source a battery and or a

    supercapacitor bank - on board or hybrid meaning with another major power source on board as

    well that is not electric. That may drive the wheels when extra power is needed ie a parallel

    hybrid or simply charge the battery a series hybrid.

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    2. Why have them?

    Military forces have many reasons for deploying hybrid electric and pure electric vehicles. Forexample, they can be silent and almost free of vibration as is useful in a robot bomb disposal

    vehicle or a stealth vehicle used for surveillance.

    Fig. 2.1 Electric stealth vehicle

    Source BAE Systems

    Fig. 2.2 General Dynamics Land Systems Shadow hybrid electric vehicle

    Source Department of Defense USA

    Some versions employ the long range, high power benefits of a hybrid drive train but revert to

    pure electric when stealth is needed. Indeed some electric vehicles can provide extra electricity

    for other equipment at destination, permitting silent operation of radar and so on. But there is

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    more. A military force is usually limited in mission by its supply chains and a major part of that is

    always supply of fuel.

    The US Army sees hybrid-electric powered trucks and the hybrid-electric Future Combat SystemsFCS as key in its objective of 75% lower fuel consumption by 2020. This is as much to do with

    operational flexibility - permitting previously impossible speed of deployments - as

    cost saving and reduction of pollution. Significant savings have already been demonstrated.

    Operating as a hybrid, with a 24-gallon tank, a truck travels 375 miles without refuelling

    compared to a conventionally powered vehicle, travelling less than 60% of that range. Primarily,

    savings do not relate from the cost of fuel itself, but to reduced army logistical transportation

    requirements - as fuel takes up about 70% of the logistical tonnage haul in a heavy armored

    division.

    Fig. 2.3 Millenworks light hybrid vehicle

    Source Millenworks

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    Fig. 2.4 Hybrid Future Tactical Truck System (HFTTS)

    Source DOD

    Fig. 2.5 Oshkosh hybrid military Heavy Expanded Mobility Tactical Truck (HEMTT)

    Source Oshkosh

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    Fig. 2.6 100mpg(US) Hybrid Hummer

    Source Hummer

    Fig. 2.7 Bronco hybrid from Singapore

    Source ST Kinetics Singapore

    Even hybrid battle tanks are being designed. Therefore, whereas less than 1% of military vehicles

    are electric today, something near to 40% is likely by the end of the decade on IDTechEx

    projections. As early as 2016, we forecast over 35,000 electric military land vehicles being sold at

    a total cost of over $3 billion. Often, the design requirements of military, security and police

    electric vehicles are similar. Add to that the many marine and airborne electric military, security

    and police vehicles both manned and unmanned. As the technology and its employment

    broadens, there are many other advantages coming to the fore. For example, it is easier to have a

    physically distributed and multiply redundant power train if it is electric. Electric power trains can

    be more reliable, easier to repair and last longer. We shall even discuss structural batteries and

    smart skin coming along where power electrics and electronics become part of the structure of

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    the vehicle. In all cases, reduced maintenance is welcomed in military applications because that

    equates to greater security and operational flexibility not just cost control.

    The German Army, Deutsche Bundeswehr, recently demonstrated two of their military vehiclescurrently in use. There was an all- terrain unmanned surveillance electric vehicle a little larger

    than a quad bike and the unmanned smaller robot vehicle with surveillance camera shown below.

    Fig. 2.8 Roboterwerk robot electric surveillance vehicle

    Source IDTechEx

    Green Wheel of China demonstrated the following all-electric jeep style vehicle at eCarTec in

    Germany in October 2011.

    Fig. 2.9 Green Wheel jeep style pure electric vehicle

    Source IDTechEx

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    3. Marine military vehicles

    On the sea and on inland waterways, some craft need to be silent and have as little heat and gassignature as possible to make it difficult for hostile missiles to impact, just as is the case in the air

    and on land. However, marine electric vehicles also include a large program of deployment of

    Autonomous Underwater Vehicles AUVs. Nowadays, most of the military ones used for

    reconnaissance, surveillance, search and rescue and other purposes are large and expensive

    being up to 20 meters long and using some of the largest batteries in any electric vehicle. These

    cost up to $5 million each.

    Fig. 3.1 Swimmer type of AUV

    Source CMERI India

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    Fig. 3.2 Hypersub submersible fast powerboat

    Source MarionHSPD

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    4. Military aircraft

    Military aircraft are mainly Unmanned Aerial Vehicles (UAVs) and that will continue to be thecase for the next decade. There are civil manned aircraft but they are small single and two-seater

    propeller driven craft. When pure electric they have range of only 100 miles (160 km) or so and

    endurance of about one hour or two. This is of limited use to the military but progress is rapid.

    For example, a hybrid electric aircraft first flew in 2011 with potentially much longer range.

    Boeing and its largest competitor EADS in Europe are developing the ability for even the largest

    air transporters and airliners to be independent when on the ground by becoming electric

    vehicles thanks to an electric motor on the nose wheel. This is of enormous significance to

    military forces because it increases the range of aircraft by having the jet engines switched on

    only the instant before takeoff saving the megawatts of power wasted queuing for takeoff and it

    lets the pilot dock the aircraft silently after landing, without the vulnerability of waiting for

    ground support equipment.

    Fig. 4.1 Boeing/ WheelTug electrified nosewheel uses Auxiliary Power Unit APU in large aircraft

    whereas the EADS version uses a fuel cell.

    Source WheelTug

    The AeroVironment Raven, the best-selling hand launched surveillance aircraft is pure electric

    and over 12,000 have been used by military and security forces from Australia to North America

    and Europe,.

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    Fig. 4.2 AeroVironment Raven, the best-selling hand launched surveillance aircraft

    Source AeroVironment

    The Aqua Puma version lands on water

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    Fig. 4.3 Aqua Puma

    Source Royal Australian Navy

    Very small surveillance aircraft are now being proved and some examples are shown below.

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    Fig. 4.4 Very small UAVs for surveillance etc

    Source Rotomotion, AeroVironment, DARPA

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    5. Key enabling technologies

    5.1. Introduction to the six key enablingtechnologies

    The following are the six key enabling technologies that will confer optimum cost, safety, security,

    reliability, life and performance to land, sea and air military electric vehicles over the next decade.

    Table 5.1 First major use of new electric vehicle technologies

    Source IDTechEx

    For example, wireless transmission of energy has been largely developed for consumer

    electronics and non-military electric vehicles but it is leading to continuous power acquisition

    resulting in small or no traction battery being needed. Anyway, wireless charging of the vehicle

    traction battery when stationary is executed without the driver leaving the vehicle, so it is safer

    and cleaner. For more on this see the IDTechEx report, Wireless Power Transmission for

    Consumer Electronics and Electric vehicles 2012-2022.

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    Traction batteries

    Traction motors

    Electronics/electrics such as battery management System BMS, on-board chargers, motor

    controllers, and the Vehicle Management System that manages these with interfaces tocontrols and instruments, energy harvesting, supercapacitor banks etc.

    Range extenders

    Supercapacitors

    Energy harvesting such as regenerative braking by reverse motor, generator or flywheel,

    dampers that generate electricity and harvesting heat from the hybrids engine and exhaust.

    However, although military vehicles pioneered almost all of the most advanced technologies

    some years ago, that is no longer the case today and benchmarking with all forms of non-military

    vehicle is now extremely important.

    5.2. Traction batteries

    Military vehicles occasionally use single use batteries but the vast majority of configurations

    employ rechargeable batteries where lead acid and nickel metal hydride versions are on the way

    out because of performance inadequacies such as weight, space, poor handling of power surges,

    short life, memory effect, self-discharge etc.

    Fig. 5.1 Third generation lithium-ion battery, the lithium sulphur small UAV battery of Sion

    Power

    Source Sion Power

    For the next decade, lithium-ion batteries will strongly dominate the traction battery scene for

    military electric vehicles but there are variants. During the next ten years, we shall see some

    progress from second generation lithium-ion batteries that have a better cost-performance-

    safety compromise, notably those with lithium ion phosphate or low cobalt cathodes, lithium

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    polymer electrolyte construction (sold polymer with gel and no separator) and carbon or lithium

    titanate or other advanced anodes. Next come traction batteries with higher energy density,

    often of flat construction to improve performance. First of these to be used is lithium sulphur

    batteries already deployed in several unmanned aerial vehicles UAVs. Lithium air and lithiumwater batteries also have a place as their problems are overcome and truly solid state

    electrolytes, typically inorganic, will lead to a great saving in containment and safety sy

    including cooling. Indeed, third generation lithium-ion batteries often dispense with the organic

    electrolytes the part that can catch fire and employ solid state inorganic electrolytes in

    structures printed reel to reel to create a much more robust entity. For more see the IDTech

    report, Electric Vehicle Traction Batteries 2011-2021

    stem costs,

    Ex

    Traction motors

    Here there is a battle between asynchronous and synchronous electric motors for electric

    otating

    cost

    In-wheel and near-wheel motors create redundancy and improve steering and traction and they

    l Systems

    d

    s - all

    et

    5.3.

    vehicles with little difference between the needs of hybrid vs pure electric vehicles.

    Asynchronous motors never have permanent magnets because they are effectively r

    transformers. They therefore tend to be more temperature tolerant and independent of the

    of neodymium in magnets, an element that has sextupled in price and could go higher as long as

    China controls supply. For more see the IDTechEx report, Electric Motors for Electric Vehicles

    2012-2022

    are in use in military forces to a small extent while being largely unaffordable in other

    applications despite replacing transmission and differential. For instance, Quantum Fue

    Technologies Worldwide, Inc., has its Clandestine Electric Reconnaissance Vehicle (CERV), an all-wheel-drive diesel hybrid electric vehicle designed by Quantum and TARDEC's National

    Automotive Center (NAC) with funding support from the US Special Operations Comman

    (USSOCOM). The unit can maintain speeds of 80 miles per hour and climb 60 percent grade

    while reducing fuel consumption by up to 25 percent compared with conventional vehicles of

    comparable size. QT has developed a land-based V22 hybrid reconnaissance surveillance and

    targeting vehicle "RSTV", a hybrid FMTV truck and a hybrid line hauler. The development budg

    granted by the US military for the projects was $43 million.

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    Fig. 5.2 CERV

    Source: Quantum Fuel Systems Technologies

    Fig. 5.3 TARDEC APD with in-wheel motors

    Source TARDEC

    5.4. Electronics/electrics

    The electronics and electrics in electric vehicles are merging and changing from being wired

    discrete components and bus bars in the main. Rogers Corporation saves cost and improves

    performance with its copper high current conductors bonded to ceramic in place of copper bars.

    Many companies print electrics and electronics. Overall, the amount of electrics and electronics

    in a vehicle is growing rapidly, from about 30% of cost to up to 80%. For example, the

    asynchronous motors gaining market share substitute circuits for a mechanical commutator,

    addition of energy harvesting calls for new control and conversion circuitry. The call for improved

    safety in batteries and elsewhere leads to adoption of an increasing number of wired and

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    wireless sensors. Without a Battery Management System and its cell sensors, one in 70,000

    electric vehicle would explode if the same lithium-ion battery technology as used in laptops is

    used in EVs the point being that there are 10,000 or so more cells. Charging infrastructure

    appears both in and alongside electric vehicles these days and both are linked to energyharvesting circuits. For more read the IDTechEx reports, Introduction to Printed Electronics and

    Electric Vehicle Charging Infrastructure 2011-2021.

    5.5. Range extenders

    Most hybrid vehicles today have a largely unmodified conventional engine. As hybrids trend

    towards being series hybrids where the engine never does more than charge the battery, the use

    of a conventional engine becomes increasingly ridiculous because the requirement is completely

    different and ultimately nothing much more than the equivalent of an emergency charger. In the

    meanwhile, we are talking of something as small. Low cost and lightweight as possible the onlyprovides fairly constant power (and, if it rotates, torque). Necessary power from range extenders

    is being further reduced where there is ubiquitous fast charging and multiple energy harvesting

    on-board.

    The situation with range extenders is not as simple as that with batteries (mainly variants on the

    lithium-ion battery for the next decade) and motors (two basic choices). One way of looking at it

    is to say that there are many designed-to-purpose rotating machines that attach to a generator

    via a rotating shaft. Competing with these are the less proven but more elegant fuel generators

    that inherently generate electricity.

    Examples of range extenders being used or trialled, with fuel generator versions indicated withthe red gen.

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    Fig. 5.5 Fuel cell AUV in Japan

    Source JAMSTEC

    There are many variants deployed including high temperature solid oxide fuel cells SOFC and thefavourite, the PEM being most commonly developed and used in transport. Proton Exchange

    Membrane PEM fuel cells, also known as polymer electrolyte membrane fuel cells PEMFC,

    convert atmospheric oxygen and hydrogen stored in the vehicle into water and electricity. The

    water is pure and it can be used in vehicle climate control. For all the jargon and explanation of

    many EV technologies see the IDTechEx Electric Vehicle Encyclopaedia that comes free with

    any IDTechEx EV report.

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    Supercapacitors

    Look out for deployment of supercapacitors that take over much of the function of traction

    batteries beyond todays assistance with fast charge and discharge. This will be because

    supercapacitors and later supercabatteries (Asymmetric Electrochemical Double Layercapacitors) will offer longer life and greater reliability and possibly other benefits in military

    vehicle design.

    New and improved supercapacitors and their variants such as supercabatteries are becoming

    more and more useful in EVs. They started by being used across batteries to cope with fast

    charge and discharge but some now have useful amounts of power stored yet still the

    advantages over batteries such as life of over 20 years and very high reliability.

    Fig. 5.6 New and improved supercapacitors and their variants such as supercabatteries are

    becoming more and more useful in EVs

    Source Industry

    Energy harvesting

    The main forms of energy harvesting being used or considered for military electric vehicles are

    harvesting of motion, heat and light. Primarily, capturing motion consists of the favoured

    brushless traction motors working in reverse to capture and electrically return up to 15% of

    braking energy and, soon to be introduced, dampers capturing vertical energy up to 1kW per

    damper on a large vehicle. However, complete energy harvesting active suspension is being

    researched and there are dreams of body flexing also generating energy. Wind turbines can be

    deployed when the vehicle is stationary. Air and marine vehicles achieve the equivalent of

    regenerative brakingby soaring, mooring in a tidestream or sailing with the propeller trailing.

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    Next most popular is capturing light using photovoltaics (solar cells), here the progression is

    towards transparent or translucent film over the whole vehicle, even underneath as it is

    developed to capture infrared not just light,. Indeed, in the laboratory, some photovoltaics

    captures ultra violet as well. Meanwhile, structures that unfold or expand when parked gainmore area and therefore electricity and some vehicle manufacturers are looking at self sufficient

    rear lights etc thanks to local photovoltaics, reducing the large cost and vulnerability of wiring.

    Examples include nantenna=diode photovoltaics promising flexibility with double the best

    efficiency achieved with PN junction and photoelectrochemical DSSC photovoltaics today.

    Meanwhile, we expect Copper Indium Gallium Diselenide CIGS photovoltaics to be a front runner

    for long life flexible, conformal photovoltaics. The much needed photovoltaics that harvests UV,

    visible and IR and/or that is transparent to be many years away.

    Fig. 5.7 The $517 million unmanned surveillance airship currently being made for the US

    Department of Defense by Northrop Grumman showing flexible photovoltaics.

    Source Northrop Grumman

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    Fig. 5.8 Glider type of AUV surfacing to recharge batteries using wave power (by hinging) and

    solar power (by photovoltaics)

    Source Falmouth Scientific

    Printed electronics and electrics

    Printed electronics and electrics will save up to 40% of weight, space and cost of control clusters

    and other human interfaces and wiring in electric vehicles, eventually encompassing much of the

    battery pack electrics and electronic circuitry and several forms of energy harvesting feeding the

    battery, multi-mode harvesting becoming commonplace, first in marine military vehicles the in

    air and land military vehicles.

    Structural components and smart skin

    Dumb vehicle bodies and chassis will progress to smart forms with advanced structural

    composites married to smart skin performing many functions including energy harvesting,

    storage and sensing condition in real time. Something of a halfway house is the incorporation of

    components into the body of the vehicle as with T-Ink printed tape replacing the much bulkier

    and heavier copper wire. Then there are the structural batteries in the Drayson racing cars being

    built in the UK in 2012 that have lessons for the military. Battery geometry is changing with this.

    Flat, wide batteries employed in aircraft wings, such as those of surveillance UAVs at over 10,000

    meters up turn out to have faster charge-discharge and simpler cooling when well-made and this

    IDTechEx Ltd 2011US Tel: +1 617 577 7890

    UK Tel: + 44 (0)1223 813703

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    Military Electric Vehicles - Where, Why, What Next?

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    30

    is now being applied to land vehicles. Add that to the conformal thin film photovoltaics now

    favoured, the capacitive skin that destroys incoming ordnance, printed logic and power circuits

    and so on and clearly various forms of smart vehicle skin are on their way for land, sea and air

    vehicles. That happens inside as well as outside, as with the printed and laminated T-Ink lightingand controls that release up to 40% of space, weight and cost of dashboard and overhead

    instrumentation. In-wheel motors are another devolution of function to the outer parts of the

    vehicle.

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    Military Electric Vehicles - Where, Why, What Next?

    6. IDTechEx Electric Vehicles Reports

    Table 6.1 IDTechEx Electric Vehicles Reports

    Electric Vehicles by ApplicationAll these reports forecast numbers, ex-factory unit value and total market value for ten years

    MASTER REPORT

    Electric Vehicles 2012-2022

    Industrial and

    Commercial

    Electric Vehicles

    2012-2022

    Electric Buses and

    Taxis 2011-2021

    Electric Vehicles

    for Military, Police

    & Security 2011-

    2021

    including

    land, sea and air

    Hybrid & Pure

    Electric Cars

    2011-2021

    Light Electric

    Vehicles 2011-2021

    including e-bikes

    and mobility

    vehicles for the

    disabled

    Electric Aircraft

    2011-2021

    including

    manned and

    unmanned

    aircraft and

    airships

    Marine Electric

    Vehicles

    2011-2021

    including surface

    craft, AUVs,

    private &

    commercial

    submarines, sub-

    aqua scooters

    Electric Vehicle TechnologiesAll these reports forecast numbers, ex-factory unit value and total market value for ten years except for the Advanced Energy one

    Electric Motors

    for Electric

    Vehicles 2012-

    2022

    Range

    Extenders for

    Electric

    Vehicles 2011-

    2021

    Electric Vehicle

    Traction

    Batteries 2011-

    2021

    Car Traction

    Batteries The

    New Gold Rush

    2011-2021

    Advanced

    Energy Storage

    Technologies

    Patent Trends

    and Company

    Positioning

    Energy

    Harvesting for

    Electric

    Vehicles 2011-

    2021

    Electric Vehicle

    Charging

    Infrastructure

    2011-2021

    Wireless Power

    Transmission

    for Consumer

    Electronics and

    Electric

    Vehicles 2012-

    2022

    Geographical

    Electric Vehicles in East Asia 2011-2021

    with forecasts for China, India, Japan, South Korea, Other East Asia

    EV Encyclopaedia free with each publication

    For further details and to purchase please visit www.IDTechEx.com/reports

    31

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