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Bosch kit for the electrification of boats

Bosch Engineering, subsidiary of Bosch Group that offers complete engineering services, from the initial study to the mass production, presents its first electrification kit for the boats under 24 metres of length. The kit is composed by three key components: control unit, 400 V electric motor and inverter with integrated DC/DC converter (INVCON).

The design of Bosch synchronous permanent magnet high-speed 400 V motor grants high power density and efficiency. Moreover, the motor can be supplied with two power variants: one with maximum peak of 90 Kw and a weight of 30 Kg, the other with maximum power of 140 Kw and a weight of 63 Kg. Due to its compactness, the two versions can be easily housed in already existing systems, too.

The inverter with integrated DC/DC converter, with a maximum power of 140 Kw, generates three-phase alternating current with variable frequency starting from the direct current of the battery, while it works in reverse in the recovery phase, when it acts as generator. Due to its small sizes, it is extremely compact and easily integrated into the boat.

Gianfranco Fenocchio, General Manager Bosch Engineering Italia, stated: «The nautical industry and the sea economy in general stake on sustainability and innovation, issues cared by Bosch Group. The electrification of boats represents the most important step to allow the sector to pursue the sustainability way. For this reason, starting from Bosch’s great tradition in the automotive and off-highway sectors, we are going to provide technological solutions in the boating sector, too».

Magnets, fast development and prototyping

How important is it to find the right magnet for an electric motor, actuator or sensor? As much as it can be a difficult and time-consuming process for automotive suppliers. In addition to supplying magnetic components and assemblies, Goudsmit Magnetics based in Waalre, also offer services that speed up the time-to market for automotive manufacturers. Therefore, a key role is played by the knowledge of magnetic calculations, FEM calculations and 3D simulations that contribute to the development of a magnet or assembly that not only meets all requirements but, even before the prototyping phase, provides certainty about the correct operation.

The quality of magnets is essential to guarantee optimal operation. Magnetic measurements and quality control measurements are an important part of determining the quality of a magnet. These measurements provide automotive suppliers with guarantees and are a standard part of the IATF16949 process. Using FEM simulations, engineers and product developers have a 3D visual of how the product behaves within a magnetic system. For example, in terms of the depth of a magnetic field or magnetic flux density on another ferromagnetic object. This not only validates the overall performance of a component, but also shows its magnetic performance. In this way, it is possible to optimize product performance, resulting in the best possible solution for a specific application. Such simulations accelerate the development and prototyping process because the shape, grade and size of a magnetic component can be quickly determined.

An award for the innovative propulsion system

Transfluid, together with Genevos, has been awarded with the prize for the innovative propulsion system of the 2022-year. The awards Electric & Hybrid Marine Europe Expo celebrate the innovative developments of the marine sector and analyse the various technological areas referred to electrification and decarbonization.

Who are the winners

Transfluid is a brand renowned worldwide in the production of hybrid transmission units and electric motors and it offers 2 kW solutions, as well as 250 kW ones, and with the hydrogen-electric combination for hybrid propulsions it provides from 50 kW up to over 1500 kW. Genevos, instead, is specialized in the integration of fuel cells for marine applications. The two players have collaborated to join their competences, in a scalable zero-emission propulsion package.

The innovations

The partnership contributes in the acceleration of the green marine mobility through the supply of a turn-key hydrogen-electric propulsion system based on maritime certified technologies. The offer of a complete system will include the range of hydrogen power supply modules (HPM) recently AiP-certified by Genevos and Transfluid propulsion systems, DNV certified, for marine applications.
The broad range of Transfluid electric products in combination with HPM line that offers 2 kW- 250 kW solutions, in addition to the hydrogen-electric matching for hybrid propulsions from 50 kW up to over 1500 kW allows achieving flexible highly innovative solutions and it permits to satisfy the requirements of the marine market.

Motor in the wheel for Lightyear’s utmost performances

We had already talked about that, because it is the startup renowned for implementing Lightyear 0, the sedan with photovoltaic panels, recently presented in its definitive version. Today, the Dutch player is a hot topic again, due to the collaboration with the company Elaphe, specialized in zero-emission powertrains, with which it is going to boost its sedan to record efficiency.
The great news? Precisely the implementation of one of the most efficient in-wheel electric motors in the world, precisely so: inside the wheel. According to Lightyear, with this modified Elaphe motor, they have succeeded in reaching 97% efficiency, losing a small percentage of energy under the form of heat.
The motor, which has been placed inside each wheel of Lightyear, is based on modified Elaphe motor. The supplier of materials is Aptera, which has even allowed Elaphe to work in its factories in Slovenia.
The unit is currently facing the test phase that lead to the validation of the project and of the manufacturing method.
Worth reminding that the production of the electric sedan will soon start in Finland and will be ready on the market at the beginning of 2023.

First prototype 500KW electric motor for Hybrid Air Vehicles

Collins is developing 500KW motor as part of a family of electric motors, suitable for the Airlander 10 aircraft, that can be scaled up or down to meet the needs of potential applications across multiple aircraft segments. All this is fruit of the partnership with Hybrid Air Vehicles and the University of Nottingham.
For the 2,000 RPM permanent magnet electric motor, Collins is targeting specific power density levels of 9 kilowatts per kilogram and 98% efficiency through the use of a novel motor topology and composite construction. Collins is designing the motor at its Electronic Controls and Motor Systems Center of Excellence in Solihull, UK, where it’s also developing its 1-megawatt electric motor and motor controller for the Pratt & Whitney Canada (P&WC) regional hybrid-electric flight demonstrator. The two motors are part of Collins’ technology roadmap for the development of a family of electric motors that can be scaled up or down to meet the needs of various hybrid-electric and all-electric applications across multiple aircraft segments.
Airlander 10 is scheduled to begin hybrid-electric operation in 2026, followed by all-electric, zero-emission operation in 2030. To achieve this, the aircraft’s four fuel-burning engines will be replaced by Collins’ 500 kilowatt electric motors—beginning with the two forward engines in 2026 and the two rear engines in 2030.
Tom Grundy, CEO of Hybrid Air Vehicles said: «The development of electric motors for Airlander 10, with Collins Aerospace and the University of Nottingham, is a crucial part of our pathway towards a future of passenger and freight transport that produces zero emissions. It is great to see the programme develop with the different organisations working in unison to deliver the right electric motor for the job».

BMW patents the electric motor with opposite cylinders

The heat dissipation is a very serious problem in electric vehicles, especially referring to the temperatures of batteries and fast battery chargers. Concerning this, patent proposals by BMW concern external cooling elements, with large fins that exploit the race air to dissipate the heat transmitted to them by the elements hosted inside: motor, battery or control unit. It is a solution that might be used also as heat exchanger for some liquid-cooled elements. So, it would really be bingo: on one hand the cooling, on the other hand maintaining those two opposite cylinders that are a distinguishing element for BMW.

Novelties in pure synchronous reluctance motor ambit

As energy costs climb, the need for the highest level of energy-efficient pumping equipment has never been more critical. Nidec Motor Corp. has responded to that demand by introducing SynRA™, an innovative, patent-pending synchronous motor.
The SynRA variable frequency motor provides the starting benefit of an induction motor, the operating benefit of a pure synchronous reluctance motor, and suitability benefit from the simple volts/hz drive.
When paired with the ID300 Perfectspeed™ integrated drive, the new motor offers high efficiencies for industrial and commercial pumping and Hvac equipment – with ratings at IE 4 and IE 5.
In addition to significant energy savings, this new technology from Nidec’s U.S. Motors® brand offers the advantage of easy motor replacement, without having to install an entirely new system and controls, saving time and money.
The unique design gives the freedom to replace components individually instead of the entire system, leading to a lower cost of maintenance
The synchronous reluctance rotor with an aluminum cage design is magnet-free, allowing for easy programming and compatibility with existing Variable Frequency Drives (VFDs). The SynRA™ motor is also available already fully integrated with Nidec’s ID300 PerfectSpeed.

The aero-taxi by AutoFlight has passed the first transition test

Great success for the first recent transition flight test of Prosperity aero-taxi with vertical take-off by the Chinese company AutoFlight, which has risen to an altitude of 150 metres, reaching a maximum speed of 198 km/h. A transition occurs when a plane moves from a vertical to a horizontal motion and it is one of the most committing parts for an eVTOL.
The vertical test flight of the Prosperity I concept has needed eight rotors to lift the 1,500 kg of the electric aircraft into the air. Once the plane has reached an altitude of 150 metres and the relative speed of 160-170 km/h, the fixed-wing part of the eVTOL has generated a lift. In this stage, Prosperity I has entered the transition phase: top rotors have stopped turning and are blocked in an aerodynamic position whereas rear propellers have pushed the aircraft forward as a conventional fixed-wing aircraft.
However, let us go back to the plane: Prosperity I is an innovative eVTOL with declared autonomy of 250 km at a maximum cruise speed of 200 km/h. The design is lift & cruise, with the passenger pod surmounted by a pair of big wings, equipped with long propulsion pods.
AutoFlight hopes to obtain the certification with both the Chinese CAAC and with the European EASA within 2025 to perform the function it has been designed for: short transfers among city zones, transfers to the airport and connections between two neighbouring cities, so avoiding the road traffic. It is estimated that a travel taking hours by car will be reduced to about 10 minutes with eVTOL, without being less safe or more expensive than a taxi ride.

Testing facilities: innovation in UK

MAHLE Powertrain has announced the completion of two new facilities in Northampton, the result of a ÂŁ15m (US$18m) investment over the last five years.
The purpose-built facilities allow MAHLE Powertrain to support customers with the development of decarbonized propulsion technologies, with a focus on mobility, safe testing of vehicles, batteries, and hydrogen technologies under extreme simulated environmental conditions.
The center was declared open for business by Andrew Lewer, MP for Northampton South.
«We’re extremely proud of our new test facilities which complement our end-to-end development process – said Simon Reader, MAHLE Powertrain’s managing director – As the industry accelerates the development of a new generation of vehicles that will offer carbon-neutral solutions for the transport sector, it creates a huge demand for testing facilities. Our new center has been designed with both battery and future-fuelled vehicles in mind and provides a spread of capabilities that is almost unique anywhere in the world».
The new Vehicle Development Centre (VDC) allows manufacturers to test both two and four-wheel-drive vehicles in a variety of conditions and circumstances, without international travel. The facility can replicate the conditions of arctic climates, deserts, tropical rainforests and mountainous regions. The facility also supports the testing of hydrogen-fuelled technologies by monitoring and safely venting any escaping gases.
Andrew Lewer, MP for Northampton South, said: «I’m delighted to be able to declare this important new facility open for business. MAHLE Powertrain’s investment recognizes the huge wealth of engineering talent in this country, and this region in particular – a stone’s throw from the heart of British motorsport – with 160 skilled technicians and engineers already employed at the site».

Vitesco stakes on synchronous electric motors with external excitation

Great technological novelties: Vitesco Technologies has presented its new electric synchronous motor with external excitation, which does not need the use of expensive metals or rare earths. The unit was designed to ensure high efficiency and high travel speed, ideal to be used on electric vehicles featuring high-performances or long distances.
PMS (Permanent Magnet Synchronous) motors contain magnets made of expensive, and not always easily provisioned, rare earths. Together with this drawback, Vitesco highlights also the fact that electric vehicles are evolving quickly and are improving in terms of performances. Instead of magnets, electric synchronous motors with external excitation have some coils that do not need rare earths.
The new line of such Vitesco motors has been implemented with power electronics included and it is compatible with transmission systems manufactured by the company itself.

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