There are various improvements to enhance energy density in stator windings in the meanwhile, with applied sciences like axial flux motors gaining momentum. On the opposite aspect, radial flux motors with hairpin windings are getting pushed to new limits when it comes to effectivity and industrialization.
WAFIOS is the world chief in wire bending for nearly 130 years, and is at all times up for brand new challenges.
For the purposes of flat wire edge-wise winding, WAFIOS got here up with a novel new tooling idea that permits the utmost attainable fill think about an axial flux stator. The flexibleness of the CNC tools makes it attainable to fabricate axial flux motor windings full on one machine, with out further course of steps.
This tooling idea may also be utilized to inflexible busbars as much as 200mm², an thrilling product that WAFIOS has been delivering manufacturing cells globally since 2014.
Be part of this presentation at our Spring Digital Convention on EV Engineering, offered by WAFIOS, to study extra about versatile wire forming options, stator winding, and energy density!
Different classes at our Spring Digital Convention embrace:
Electrical Insulation Supplies In E-Drives: Sustainability. Efficiency. Effectivity.
The electrical trade has seen a wave of latest improvement in the course of the previous decade. E-mobility and power transition in the direction of renewable sources have been key drivers to this evolution with none doubt. But new advances enable bettering the sustainability of e-drives even additional, be it via new motor designs or supplies that enable for much less copper or electrical metal in an electrical motor. Metals make up for the key portion of value in electrical machines, thus metallic utilization and amount of metallic used are driving the CO2 steadiness in an analogous method as value. Key enablers have been thermally conductive insulation supplies and supplies with exceptionally excessive thermal score in addition to improved thermal administration of the lamination metal core through the use of novel becoming a member of applied sciences, like Backlack know-how.
Enhancing the carbon footprint by saving metallic is a serious driver, nevertheless, Axalta retains engaged on the sustainability of insulation supplies itself. Impregnating resins are more and more switching from styrene or vinyltoluene based mostly supplies in the direction of epoxy or acrylate supplies with out volatiles, decreasing emissions and bettering operators’ lives considerably. Electrical metal coatings are nearly completely waterborne and superior supplies have eradicated Chromium (VI) from their formulations. Additional, the elevated use of renewable uncooked supplies will assist to decrease carbon footprint.
Wire enamels are utilizing coal-based solvents (phenol, cresylic acid and so on.) or low molecular amides (NMP, DMF, DMAc). Axalta takes on the problem to interchange these feedstocks by extra environmentally and user-friendly solvents, decreasing toxicity and hazard on the store ground stage. Additional, coal as a feedstock may even see extra dynamics sooner or later as a result of power transition itself. Following this method the general manufacturing course of value will be saved on the similar stage as the present state, eliminating particular storage situations or exhaust air therapy by bettering the extent of fabric utilization, whereas protecting efficiency no less than on the identical stage as standard supplies.
The Key Elements Of Hairpin Stator Impregnation For EV Motors
The launch of the hairpin know-how utilized to electrical traction motors has modified the idea of conventional impregnation. Tecnofirma has dedicated itself to analysis modern strategies to proceed acquiring high-quality ranges.
In a latest research performed in collaboration with the Politecnico di Milano, Tecnofirma has developed a theoretical calculation methodology that’s consultant of the capillarity of the resin utilized to a hairpin motor. This new methodology assesses—in an analytical and experimental manner—the variables that work together probably the most and decide the standard of the impregnation course of.
Broadcast dwell April 4 – 7, 2022, the convention content material will span the EV engineering provide chain and ecosystem together with motor and energy electronics design and manufacturing, cell improvement, battery programs, testing, powertrains, thermal administration, circuit safety, wire and cable, EMI/EMC and extra.