its processing power, AI can act as a virtual design assistant by optimising motor configurations for specific applications. This translates to the creation of EV motors with unparalleled efficiency, power output and performance. Imagine motors tailor-made for a specific driving style or vehicle type, maximising both range and power delivery – the possibilities are vast. Furthermore, AI can continuously learn and improve its design capabilities with each iteration.
y the end of 2024, over 25% of all new passenger car registrations will be electric. The global EVmarket, valued at £291.5 billion in 2023, is projected to more than double to £714.9 billion by 2030.
I believe we’re in the initial chapter of the EV revolution, writes John
Morehead, principle consultant at Motion Mechatronics and advisory board member at CWIEME Berlin. With continued government incentives fuelling consumer adoption, and advancements in electric motors promising both longer ranges and lower costs, the following trends are poised to accelerate:
Rare earth magnets have long been a staple in electric vehicles. The reliance on these, however, presents a challenge. Currently, these are sourced from a single country, and concerns have been raised about the sustainability and environmental issues stemming from mining and processing this element, as well as supply chain security. Researchers and companies worldwide are actively trialling rare earth-free
alternatives. Niron Magnetics, for example, is manufacturing Iron Nitride- based, ‘clean earth’ magnets. Iron and nitrogen are readily available elements. In addition, iron nitride’s lower cost can translate to more affordable EVs and offer better temperature stability.
Less well-known but equally promising is niobium, a metallic element. Unlike traditional motor statorsmade fromsilicon steel, niobium has the potential to be transformed into nanocrystalline soft magnetic materials. These advanced materials boast superiormagnetic properties, leading to significantly reduced eddy current losses within the stator. In axial flux motors – a design gaining traction for its compactness and efficiency – niobium-based stators could potentially improve overall motor efficiency, translating to a longer driving range on a single charge. Companies like CBMM andWEG are pioneering the use of niobium in motor construction. The partnership’s experimental validation tests prove the benefit: nanocrystalline material containing niobium slashed motor total losses by 53%. This translates to a significant 6.7 percentage point increase in efficiency compared to the same project built with traditional silicon steel. This holds the promise of not only more efficient motors, but also potentially lighter ones. The positive impact of niobium research may even extend beyond motors.
Early research suggests its unique properties could pave the way for the development of next-generation batterymaterials.
The industrial potential of 3D printing is shaking up the traditional method of motor stator production, where thin steel sheets are meticulously stacked and laminated. 3D printing offers the ability to create complex internal geometries within the stator core, opening doors for optimisingmagnetic flux paths, potentially leading to significant improvements in motor performance and efficiency. It allows for the creation of intricate stator configurations not possible with laminations for potentially enhanced performance or efficiency. Furthermore, 3D printing offers a more streamlined production process.
Traditionally, motor design relied on engineers balancing various factors like efficiency, power output and size constraints. However, by harnessing the capabilities of AI algorithms, manufacturers can now analyse vast amounts of data related to motor performance, thus allowing AI to identify complex relationships and patterns that might elude human engineers. The impact of AI on motor design goes beyond mere analysis. By leveraging
Studies by the International Federation of Robotics (IFR) show an 11% average annual growth rate in industrial robots installed globally between 2015 and 2021. This trend is only going to continue, particularly within the EV motor industry. Robots can handle repetitive tasks with unmatched precision – aMcKinsey
report estimates that automation can potentially reduce defect rates by up to 90%, leading to improved in motor reliability. Furthermore, automation allows for faster production cycles, enabling manufacturers to meet the ever-increasing demand for electric motors driven by the growth of the EV market. These emerging trends paint a transformative picture for the electric motor
industry. This confluence of innovation signifies a powerful shift towards a future characterised by three pillars: increased efficiency, unwavering sustainability, and relentless innovation. By pushing the boundaries of what’s possible, we can ensure the electric motor industry remains on a progressive trajectory, paving the way for a more sustainable and electrifying future for e-mobility.
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