Wednesday, May 18, 2022

A super electric motor incoming

Winding-free, featuring excellent performances, low weight and volume. Here are the main features of the new motor at which is working the Emilia company Poggipolini, top player in titanium fasteners for Formula Uno and aerospace. The new motor will address aerospace and defence, but also the world of the electric traction for Motor Sport and high-end cars.
Concerning this, a key role will be played by the factory of the future “Speed Up Lab”, headquartered in the new factory at San Lazzaro di Savena, in an area of over 20,000 sq. m., close to the Manufacturing Center of Excellence inaugurated in 2019. Its mission is working in open innovation.
Recently, the company has established a partnership with Puglia startup Roboze to design and to manufacture the mechanical parts of electric motors, 3D printed with innovative materials such as Carbon Peek, a carbon-reinforced polymer. The collaboration will aim at accelerating the adoption of this new process technology, shifting from engineering to industrialization.
The technology of the new electric motors will be fully innovative and will precisely concern its operation, as well as materials, which will assure lower weight and simplification of architectures and manufacturing processes.

In Berlin the new engineering centre for Bugatti Rimac

In the German capital, a new design and engineering hub will be established and it will operate under a new German subsidiary called Bugatti Rimac GmbH. Berlin is a young and sparkling city, able to fuel technological start-ups, an epicentre for artists and designers.
However, the automotive company’s headquarters will always remain in Zagreb, with the vast majority of employees and a future expansion in Croatia.
It seems that some job positions are already open: Concept Chief Engineer, Head of High-Voltage Systems and Components, Head of Fine Mechanics and design roles with specific focus on interiors, exteriors and VR.
Adriano Mudri, previously design director of Rimac Automobili, will be appointed design director of a future sister company of Rimac focused on mobility, which will take care of developing state-of-the-art vehicles, which will be successively revealed.
«Bugatti Rimac GmbH – stated its CEO Mate Rimac – represents a new exciting business expansion. This new branch will be deeply involved in many new exciting hypercar designs we are looking forward to sharing with the world. Our team is expanding day by day and Bugatti Rimac GmbH represents an opportunity for the best in the sector to join us, to prove their skills and to be part of a company that is redefining the hypercar».

A novel powder-metal based TFM electric motor

Eckart Schneider, Director Business Development of GKN Powder Metallurgy, has communicated on his professional social channels he is designing and building a novel powder-metal based TFM – transversal flux motor – electric motor for the yet lightweight Novus e-motorbike. «Believe it or not, it’s going to push 5 times more torque than my beloved old flat-twin boxer engine or still up to 3 times more than the newest 1250cc 4V boxer engine at only 1/3rd of its weight». GKN, British multinational whose core activity is the implementation of components intended for industries in the automotive and aerospace sectors, has also recently announced its new Advanced Research Centre – created to develop next-generation eDrive systems powering future electrified vehicles and increase engineering capability in the UK to meet Net Zero commitment.
GKN Automotive is partnering with the University of Nottingham and Newcastle University to push the boundaries of eDrive technology and accelerate modular innovation. The world-class collaboration will focus on the development of ultra-high efficiency EDUs for future electric vehicles.

DiaPro 4.0, the study for motors’ sensors

Recently, at the scientific-technological pole of University of Ferrara, they have held the conclusive presentation event about the research activity results of DiaPro 4.0 project.
The target consisted in developing an innovative multi-sensor system for the malfunction detection and the forecast of future “health conditions” in rotors, gears, bearings and electric motors.
DiaPro4.0 has involved industrial research laboratories accredited to the Regional Network for High Technology with expertise in the field of mechanical transmissions and of diagnostics/prognostics, like MechLav, Intermech and Raw Power, and Bonfiglioli spa and Marposs enterprises. Current predictive maintenance systems for drives and gears feature reliability limits owing to the variability of operational conditions and incompatible costs with the application on medium-small geared motors.
The implementation of a demo-prototype of a multi-sensor system of predictive maintenance, based on Edge Computing architectural solutions, with forefront characteristics compared to current system, has led to a 30% -50% lower cost of the industrialized system compared to the available systems on the market, in addition to high diagnostic reliability.

Vitesco focuses more on Asia-Pacific region

Vitesco Technologies has inaugurated its new research and development center in Tianjin, China. From there, the company, a top player supplier of advanced powertrain technologies and e-mobility solutions, will increasingly serve the Asia-Pacific region with hybrid and electrified powertrain technologies to meet the rapidly growing e-mobility market. The new research and development (R&D) center have a gross floor area of 9,000 square meters and provides space for around 500 employees.
«Tianjin – said Andreas Wolf, CEO of Vitesco Technologies – is one of our most important locations in China, the world’s largest automotive market. With this new research and development center, we are expanding our capacities precisely where we expect the greatest growth in e-mobility».
Headquartered in Regensburg, Germany, in Tianjin Vitesco Technologies develops battery, motor and electronic control systems for battery electric, full hybrid and 48 V mild hybrid vehicles. The portfolio includes high-voltage drive systems, high-voltage control systems, high-voltage battery management systems, electrified 48 V drive systems and 48 V battery systems. In addition, the R&D center has a versatile laboratory for testing and validation.
The research and development center is located at the Vitesco Technologies Tianjin manufacturing site, which has been there for 26 years. Since 2019, the plant has been producing fully integrated electric axle drives (EMR3) for various customers, including PSA or Hyundai.

Ambitious electric motor goal from USA

QM Power and the SPARK Lab at University of Kentucky shared the combined results of a large-scale, multi-objective design optimization study, and lab testing of a prototype motor designed to meet the ambitious 2025 power density goals set by the US Department of Energy (DOE). The research demonstrated the high torque and speed capability of QM Power’s innovative permanent magnet motor technology. This, combined with advanced manufacturing and cooling technologies, achieved a record-high 50kW/liter volumetric power density for traction applications such as electric vehicles (EV).
The computational study was conducted at the SPARK Lab and an open frame lab prototype was designed and manufactured by QM Power. Tests and extensive simulations were conducted at University of North Carolina, Charlotte and at University of Kentucky to reveal the best outcome given trade-offs among efficiency, power density and power factor while achieving the DOE 2025 target. In 2019 the US DOE established the 2025 goal as part of an ongoing effort to reduce dependency on resources such as fossil fuels and rare earth magnets. It represents an ambitious 89% reduction in motor volume compared to 2020 targets. This project is among the programs which the DOE’s Vehicle Technologies Office deems to “have the potential to support radical new vehicle architectures by dramatic volume/space reductions and increased durability and reliability.”

Regal’s edge product tools

Regal Beloit Corporation, specialized in the engineering and manufacturing of high-efficiency electric motors and power transmission products, has recently announced its enhanced Power Transmission Solutions (PTS) Edge tools. Regal’sEdge tools include product selection modules for belt drive, bearing and gearing products and mechanical power components, as well as bearing registration and a belt drive efficiency calculator. These improved Edge tools are easier to use, mobile-friendly and fully integrated to the regalbeloit.com online product catalogue.
Edge product selection modules assist users in selecting the right power transmission mechanical components based on their specific application requirements. Once they install new bearings products, the bearing registration allows users to not only register their bearings but also manage assets on the Regal PT mobile app. The belt drive efficiency calculator helps users to calculate how much money they can save on energy consumption by using Browning™ belt drives.
«The enhanced Edge tools – said Matthew Clemens, DCX marketing specialist at Regal – allow a mobile friendly, integrated customer experience across regalbeloit.com. The modules have been updated to help point customers to common parts, versus made-to-order parts, so the primary selections are readily available».

Motor in the wheel? Here is the proposal by Hitachi

In the past, various companies have already tried developing disruptive zero-emission motors, for instance with motors hidden in the wheel. This frontier has not technically found its benefit, yet, especially owing to the weight hindrance.
Hitachi, more precisely its subsidiary Hitachi Astemo, is trying giving a solution to the problem with the Direct-Drive. In practice, the manufacturer is going to integrate everything in a single component, placing in the wheel the motor, the inverter and the brake to achieve a power/weight ratio of 2.5 kW for each kg. In this way, they can partially eliminate wirings, as well as transmission gears, so improving efficiency up to 30%.
The prototype wheel is 19″, with maximum torque of 960 Nm, operation at 420 volt and maximum power of 60 kW: multiplied by four wheels, the total value would amount to 240 kW.
To avoid undesired contacts between the inverter components and the liquid, the cooling oil circulates in a ring among the various parts, by means of tubes, directly acting on power semiconductors, and then it is conveyed to the motor to cool coils.

A new research centre on electric motors

Due to the funds coming from the RRNP and from structural funds, Turin Polytechnics will collaborate with the Municipality of Pianezza in the creation of a Research Centre for the design of electric motors. The concerned area has been reclassified as “of collective interest ” and will be redeveloped. According to this vision, they have established an agreement that will last for three years: the Municipality of Pianezza must provide the spaces and the intervention projects to allow the start of the collection of events of interest for public and private subjects interested in contributing in the creation of the Centre. In its turn, the Polytechnics will provide the necessary scientific support for the activities of research, study and training that will be held in the centre. The project will permit the conversion of territorial companies through the enhancement of the role of the industry that manufactures motors and of the entire industrial sector chain.
The Rector of the Polytechnics, Guido Saracco, stated: «With this agreement, the Polytechnics adds another important step in the process of support and development for the territorial economy and for the small medium enterprises that are going to start a process of industrial reconversion. With these synergies, we will share in further boosting economy, employment and youth’s education ».
In the photo Guido Saracco, Rector of the Polytechnics and Antonio Castello, Major of the Municipality of Pianezza (To).

University of Perugia: the study on the efficiency of electric cars is starting

One of the hottest issues concerning the electric mobility is the motor efficiency. Concerning this, a study involves the University of Perugia, in the context of a graduation course in industrial engineering. The research programme involves also professors of triennial and master graduation courses in Industrial Engineering in Terni, as well as Genesi Energia company, operating in the sector of the electric mobility engineering and of manufacturing, stocking and use of electric energy from renewable sources.
The study provides for activities of modelling and experimental analysis in electric mobility applications and the creation of predictive models for the assessment of the charge efficiency and of autonomy depending on the mileage. Such predictive models, combined with experimental checks, will be applied on Renault Zoe electric car, made available by Genesi Energia.
«The analysis of efficiency and energy dispersion of the new electric mobility – explained prof. Ermanno Cardelli, director of the Engineering department of University of Perugia – is a still unexplored field that will be fundamental to work at the implementation of the distribution networks of electric energy on roads. Moreover, the research provides for the design and the implementation of a prototype of electric quadricycle with pedal assistance with photovoltaic panels on board: the design of the super light frame, combined with renewable energy sources on board, will allow achieving theoretically unlimited autonomy in day travels».