MATERIALS | AUTOMOTIVE
Injection moulding contributes to ProLemo project
Electric single-axis drivetrains for EVs need to be lightweight if the motors are going to be used cost-effectively. The ProLemo project, organised by the German Aerospace Center (DLR) with funding from the German government, is concerned with production technologies to make this possible. Project partners from along the value chain include Arburg, which supplied multi-component injection moulding technology, as well as complex material and mould technology necessary for production of various components. Project objectives included the
mass production of parts made from iron-filled polymers, the use of lightweight materials in the rotor and rotor shaft, and the production of the motor housings from fibre-reinforced materials. The rotors are made lighter to enable higher rotational speeds as well as equal dynamics with lower power consumption. A Soft Magnetic Composite (SMC)
The ProLemo drive (top) incorporates rotor discs with different internal dimensions. The interior contour is designed as a splined version or as a low-stress hexagon version
– a PA6 highly filled with an Fe8 Ni92
magnetic alloy – was selected for the production of rotor segments. The use of this “Permalloy” makes it possible to minimise eddy current losses and heat generation, com- pared with conventional laminated rotors.
By changing mould inserts,
production of two rotor versions is possible using a single mould. The
the world’s automotive production, the share of both hybrid and fully electric vehicles manufactured in China has been set an ambitious target of 20% by 2025, which represents almost 7m vehicles.” During Chinaplas, Solvay announced significant advances in its Technyl portfolio of polyamides aimed at connectivity and autonomy in automotive. The range now comprises flame retardant solu- tions, electro-friendly products in both pure and high purity grades and a novel ion-free PA66 grade for fuel cell applications. “We have also developed a range of highly
stable Technyl orange coloured grades as we continue to innovate our portfolio for e-driven vehicle applications,” adds Batailley. “Orange is the new black for ease of identification as we focus on components designed to handle high voltages, such as connectors, circuit breakers and insulators.” Radici’s Spini cautions that even as powertrains
22 INJECTION WORLD | May 2018
exterior part of the rotor, in SMC, is the same for both versions (photo). The rotor discs are produced on a 1,500-kN Arburg Allrounder 520 A, which is equipped with a Multilift V robotic system to ensure precise removal. The cycle time is 4 mins, which means that 360 rotor discs can be produced per day, for a produc- tion of 16,425 motors per year, in one production cell.
evolve, the widespread production of pure electric vehicles is still a long way off. “The use of the internal combustion engine will continue for a good while yet,” he says. “For the next five to 10 years, we will see a lot of hybrids, so our offering will still be valid. Plus, there will be new challenges for battery systems where we can offer materials. We can develop tailor-made materials when necessary.” Spini adds: “On pure EVs, the loss of the IC engine will mean 10-12 kg less PA, but parts related to the electric drive provide potential for more than 15 kg more. Lightweighting in EVs is even more important than in cars with IC engines because of the limited range they have, so car makers need to put more emphasis on metal substitution. We are arranging our offering accord- ing to the new trend.” He cites a special type of PA66 containing 50% glass fibre as an example of a product that can replace metal in production of
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