automotive industry
which is just one example of creating much-needed test infrastructure, so that instead of looking to Europe, China and further afield, British automotive makers can stay in the fast lane for EV production in what promises to be a lucrative market. According to Greg Harris, global strategy lead for
electrification at HORIBA MIRA, the UK automotive industry is concerned about what impact the new rules of origin terms will have on supply chains and profitability. The good news is that the UK is one of the most promising places to create and build a world-class battery production sector and already has significant expertise in this area. “A great example of this is the recent investment by BritishVolt, not only to build a new £2.6bn gigafactory in Blyth, but also to site its new global headquarters at our MIRA Technology Park in Nuneaton,” he says. However, to achieve the collective aims of the
climatic, environmental and abuse testing. HORIBA MIRA says OEMs will need to source as much as they can from the UK and to implement these changes into the supply chain will require extensive development and testing, with EV battery packs being a major focus due to their high value. The organisation has responded to rising demand for advanced battery safety testing by investing £1.5m in a Large Climatic Vibration Laboratory,
❱❱ EV battery packs have a significant impact on the value added by UK manufacturers
country’s automotive industry and to continue with lucrative exports without the added burden of excessive tariffs, requires quick and strategic action by OEMs and their suppliers as well as a collaborative approach on all fronts. “The whole infrastructure for developing EVs in the UK has changed and only through investment and acceleration of R&D, academia, and infrastructure to design, test and validate batteries, as well as an overhaul of the supply chain can we make the UK competitive in the EV market,” concludes Harris. T&TH
insulation and causes a short circuit and motor failure. Very high temperature increases can cause the varnish and insulation to melt, again resulting in a short circuit. The results are always the same: the motor is ruined.
temperatures, above; which are available as a standard range as well as custom models, inset
HIGH-TEMPERATURE MOTORS There are environments in which motors need to be used where the temperatures are higher, for example drilling for oil or gas or in geothermal energy applications. Valve actuators on aircraft engines also operate in intense environments. Motor manufacturer maxon has a range of brushless HD (heavy duty) DC motors designed for these environments and can operate in ambient temperatures of up to 200˚C with a maximum winding temperature of 240˚C. The magnets in these motors are manufactured from samarium cobalt (SmCo). These magnets can reach much higher temperatures before they start to demagnetise. The copper wire used in the winding also has a higher temperature rated insulation. Finally, the impregnation varnish is rated to a much higher temperature, which ensures that the winding
remains stable throughout the operating temperature range.
SPECIFYING HIGH TEMPERATURE MOTORS It isn’t possible to increase the temperature tolerance of all motors due to higher manufacturing and material cost. The insulation on the copper wire is very rigid, which makes it much more difficult to wind. It also doesn’t work with all winding patterns. Similarly, more specialist materials cost more so over-specifying motors is an expensive approach. To specify the motor, the output speed and torque is needed as well as an understanding of the duty cycle of the motor and the electrical input supply. Environmental factors such as ambient temperature, shock and vibration exposure are needed as well as restrictions such as size and weight.
According to maxxon, a thermal analysis needs to be carried out to ensure the motor is not going to burn out in service. They also analyse the speed and torque profile over the duty cycle based on the specific ambient temperature. Such analysis provides crucial information, including winding temperature profiles and time available in the duty cycle to cool down. T&TH
March 2021 /// Testing & Test Houses /// 17
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