It is called HPM-400 the new ultra-light electric motor by Equipmake. Owing to the original intention of using it as rocket fuel pump, it features different innovations in comparison with conventional motors/inverters, making it ideal for the use in space, aerospace and marine high-performance applications. With a maximum motor speed of 20,000 rpm, peak power/torque of 400 kW/250 Nm, but a mass of just 30 kg only for the motor, the HPM-400 id deemed to rank among those featuring the highest power density in the world. In combination with its silicon carbide integrated inverter, which weighs only 10 kg, the whole system weighs only 40 kg.
HPM-400 maintains the air pressure inside and it has been completely redesigned mechanically to withstand the pressure from the interior when it goes from the atmosphere to the void. This has resulted in a super-compact cylinder package with a carbon fibre shell to keep pressure and weight low. Everything is added to an advanced high-power and low-weight motor/inverter that is at its ease in the space, in air or in water.
Ian Foley, CEO of Equipmake, declared: «The complete package is ultra-light and able to withstand unbelievable accelerations and the inverter that must operate in the void, must be at high voltage, because a lot of power is really requested».
Equipmake, for the aerospace a new ultra-light electric motor with high power density
The concept model for “k-axle” high-speed electric motor- pump unit
Recently, Kawasaki Heavy Industries, Ltd. announced its plan to unveil the conceptual model for its “K-Axle” high-speed electric motor-pump unit, which is currently under development for use in construction machinery and industrial vehicles.
K-Axle comprises three main components: a variable-displacement hydraulic pump, a high-speed electric motor with a built-in inverter, and a dedicated controller to operate the other two components. In areas such as construction machinery and industrial vehicles, conventional diesel engines are being replaced with electric motors and batteries as part of electrification efforts, in response to environmental regulations aimed at realizing a low-carbon society. Just as with electric cars, there is demand for longer operation times per charge with electrically powered construction machinery and industrial vehicles, but this has proven difficult due to installation-space limitations and cost concerns for larger-capacity batteries.
Kawasaki has developed the K-Axle by applying its high-speed, high-rotation technologies—cultivated through development of its M7V series high-speed hydraulic motors—to a hydraulic pump, and combining it with a high-speed electric motor with a built-in inverter. As a result, the K-Axle has achieved a cubic volume approximately 50% smaller than existing electro-hydraulic pumps. Additionally, the company has achieved outstanding control performance to enable high-efficiency unit operations. Together, these advantages contribute to smaller sizes for construction machinery and industrial vehicles, longer operation times, and overall cost reductions.
When brazing becomes green
Oweld oxyhydrogen gas generators have become increasingly useful in electric motor, transformer, HVAC-R and in all those industries where brazing is required. Thanks to the flexible installation, these systems are ideal for small and medium-big manufacturers.
This sustainable technology converts distilled water into green oxygen and hydrogen and replaces the old gas cylinders, traditionally used for pipe brazing (i.e., in refrigeration and air conditioning) or for wire, cable brazing in winding (in transformers or rotative equipments).
Different sizes of gas generators, with different capacities, allow to braze from small pieces up to big sections. The unit can be centralized and one or more brazing stations can be connected according to each customer need.
The company has already produced more than 8000 plants around the world, offering these solutions to the main players in the market.oxyhydrogen gas generators have become increasingly useful in electric motor, transformer, HVAC-R and in all those industries where brazing is required. Thanks to the flexible installation, these systems are ideal for small and medium-big manufacturers.
This sustainable technology converts distilled water into green oxygen and hydrogen and replaces the old gas cylinders, traditionally used for pipe brazing (i.e., in refrigeration and air conditioning) or for wire, cable brazing in winding (in transformers or rotative equipments).
Different sizes of gas generators, with different capacities, allow to braze from small pieces up to big sections. The unit can be centralized and one or more brazing stations can be connected according to each customer need.
The company has already produced more than 8000 plants around the world, offering these solutions to the main players in the market.
The main advantages are summarized as follows: the solution eliminates the gas cylinder related costs, eliminates the risk of explosions, and reducing the working pressure which is below than 0.5 BAR guarantees a total safety. The flame does not produce optical harmful radiations generating a better environment for the operator. Also, the quality of the joint is improved thanks to the pre-mixed gases by the generator which makes the technology user friendly. High skilled operators are not required.
Born in 1981 and headquartered in Sacile town (Italy), with 42 years of experience the company offers a high quality product, reliable even in tough environments.
“In a scenario where quality of brazing and health of the collaborators is increasingly a priority, companies are increasingly focused on using smart brazing solutions that help in reach these goals. For this reason Oxyweld will assist visitors with technical information and live demonstrations. On this occasion, the entire Oxyweld staff will be a disposal for any question” Diego Andreetta, Oxyweld Sales Director.
Oxyweld with its Oweldbrand will participate at 2023 Coiltech Expo ( the international exhibition for machinery and materials for the production of electrical motors, generators, transformers and winding) in Augsburg, Germany. The company will present dedicated eco-friendly oxy-hydrogen gas generators for wires, cables, bus bars brazing at booth 3-C06.
Energica, new electric platform for off-road vehicles
Energica Motor Company (Energica), top global original equipment manufacturer (OEM) is collaborating to assess a new line of electric two-wheel vehicles. Energica Inside, a business unit of Energica, is providing design and engineering services.
Livia Cevolini, CEO of Energica explained: “Our world needs to become net zero by 2050, which means transportation must become zero emission. I believe that the unique expertise and technology within Energica can help society achieve this goal faster. That is why we formed the Energica Inside business unit, and we immediately attracted a lot of attention from large OEMs looking to offer EV solutions for urban mobility, agriculture, marine, and aviation.”
Energica Inside provided a feasibility study to identify a final configuration for an off-road electric vehicle platform. The company’s engineers and designers performed a technical assessment of the OEM’s existing platform and battery pack to validate the definitive product battery specification. At the heart of the final configuration is Energica’s powertrain, which includes the E2110 motor, a liquid-cooled permanent magnet electric motor weighing just 27kg and a maximum power of 120 kW (161 hp) at 13000 rpm.
“Energica Inside is ready to help OEMs achieve their climate goals and comply with regulations by electrifying their product lines – whether its tractors, watercraft, aircraft, passenger and urban mobility vehicles” stated Carlo Iacovini, General Manager Energica Inside. “Our solutions are built around Energica’s industry-leading, proven EV design, engineering and technology.”
Energica Inside already has several projects underway, including a collaboration with U.S. electric tractor manufacturer Solectrac.
The rare earth-free Indian electric motor
In these days, the Indian start-up Chara Technologies has presented the first motor for electric vehicle fully made by using aluminium, copper and steel available in India, without using rare earths. In the specific case, it is an electric reluctance motor with artificial magnets. To make these powertrains work, some magnets are in fact necessary and rare earths are needed to manufacture them. Rare earths, besides being expensive, hardly extracted and managed, have a chain that China controls by 90% on a global scale. It is a strategy with which India is going to emancipate itself from the dependence on the supplies of minerals from foreign Countries: semiconductors are the only part of these motors recently presented imported from abroad.
Moving to Europe, we remind that in June 2022 Vitesco Technologies presented its new electric powertrain, a unit of EESM kind (externally excited synchronous motors), which does not need the use of rare earths and it is expressly conceived to be more efficient than PMS (Permanent Magnet Synchronous) units, especially at high speeds.
Ferrari, the roar of its electric motor
According to the European Regulation, all electric vehicles produced since 2020 onwards must emit a sound resembling the one of a motor based on fossil fuels, due to a matter of road safety. Noise, in fact, is important to warn both pedestrians and other vehicles about the presence of cars. In the light of this provision, Ferrari has recently registered a patent for its own electric model incoming in 2025. It is a system of sound modulation and amplification that will generate a sound exceeding 90 dB and will be modulated according to drive conditions, irrespective of the electric motor rotation.
The result? The electric Ferrari will have a motor roar also when still at the traffic light, similarly to its endothermic brothers.
Important: the sound signal has such a frequency as not to interfere with the magnetic flux of the electric motor, so avoiding generating torque and movements in the rotor that then would be transmitted to driving wheels, affecting the drive dynamics.
Rotor-stator stacks, big achievement for Feintool
One of the companies that stands out for the high-quality e-motor lamination and e-core stacks is Feintool. Recently, the company has proudly announced it is winning a project extension to supply a further 21 million rotor-stator stacks for electric motors in the industrial sector and extends long-term relationship with its customer. The expected volume will be delivered within five years, that is why Feintool is investing in new infrastructure and upgrading of equipment in the Hungary plant of the Business unit e-laminations in Tokod, Hungary.
The previous news talked about the successful cooperation started in Asia with Sitec: both technology companies have signed a Memorandum of Understanding to intensify cooperation in the production of metallic bipolar plates for fuel cells and electrolysers in Europe.
Going back to some months ago, here is the announcement by Feintool they have won a substantial contract to supply rotors and stators to a new key customer. The multi-year contract for this renowned European OEM involves a lifetime volume in the triple-digit million Euro range. This success illustrates the importance of Feintool’s strategy which focuses on electrification.
Mega-deposit of rare earths discovered in Sweden: turning point for the EU?
Besides an iron ore mine, the Swedish State mining company LKAB has discovered a deposit of over 1 million tons of rare earths in the northern area of Kiruna, in Lapland. As we know, they are strategic minerals for the production of electric vehicles, wind turbines, chips and hi-tech products. However, until now they are not extracted in Europe, but most of them come from China. Therefore, might this discovery free Europe from this existing dependence on China?
Jan Mostrom, CEO of LKAB explained: «The important thing is that we can identify quite big deposits of this material here inside the European Union, because these materials will be vital for electrification. The deposit is “enormous” and represents a first step towards Europe’s self-sufficiency ».
UK, the direction of hydrogen for heavy vehicles
From the programme Advanced Propulsion Centre (APC), HVS, Hydrogen-Electric HGV Powertrain Development, has received 30 million pounds to develop hydrogen fuel cells for heavy vehicles.
The company is one of the five that have received an amount of 73 million pounds collected by the Government of the United Kingdom and by the automotive industry to develop a green transport technology. It is a considerable amount, a piece that sheds light on the most probable direction in terms of trucks and mobility.
Currently, hydrogen fuel cells would be considered essential for heavy vehicles because lithium ion batteries used for heavy vehicles would be prohibitive and would have long recharge times.
HVS CEO, Jawad Khursheed, said: “Our mission to decarbonise heavy-duty transport in the UK has reached a major milestone with the help of the APC grant. The UK Government performed rigorous due diligence in selecting HVS to receive this grant, acknowledging that our advanced technology is a key innovation towards achieving zero-emission targets. We have successfully produced our first driving fuel cell technology demonstrator vehicle and are on track to deliver the UK’s first-to-market hydrogen fuel cell-powered HGV. We have experienced rapid growth at HVS in as little as a year, now with this government support we will boost innovation, create thousands of UK-based jobs, and build upon our goal towards cleaner HGVs.”
Electric motors, innovations for challenging applications
The big player TDK is introducing high-speed TMR front-end IC for demanding EV motor control applications and it is expanding its TMR sensor portfolio with the new Micronas ASA 2310, signal processing IC for high-speed electric motor applications in automotive and industrial environments.
The new TMR analog front-end ASA 2310 offers signal conditioning optimized for TMR-bridge angle sensors including enhanced applicative compensation features and safety supervision.
The sensors, powered and monitored by the ASA 2310, are detecting magnetic-field direction in x-y plane, and providing a SIN/COS analog voltage output which is used as input for the ASA 2310. The sensor interface and signal conditioning of the ASA 2310 are optimized for the TMR-Bridge signals.
New rotor position sensing solutions based on the ASA 2310 offer a high resolution and accurate position measurement at very high rotation speeds of up to 650,000 rpm. This enables high-speed motors to maximize torque and increase efficiency which is essential for hybrid and electric vehicles to obtain maximum range. In addition, the sensor system configuration works independently of the motor pole pair number and therefore does not require complex hardware changes, a major advantage over inductive resolver technologies. This gives more flexibility in the development of the hybrid and electric powertrains of the future.
“The ASA 2310 is a high-performance IC that extends the functionalities of a very precise analog TMR sensor and reduces the influence of noise and parasitic components caused by remote application setups where the sensor module is separate from the ECU and connected by a long wire-harness,” says Frederik Berstecher, Product Marketing Manager for „Fast Hall & TMR“ at TDK-Micronas.
Samples of the device are available now. Start of production is planned for the end of 2023.