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• In-wheel motors with a new type of motor topology and innovative inverter may increase EV ranges by >20%
• Minimized usage of magnets and iron material and cost-effective manufacturing concept make in-wheel motors competitive to central drive units
• A reduction of purchase and operating costs of electric vehicles by >4,000€ is possible
  

Interview with Krishna MPK Namburi at Nexteer Automotive

Challenges in Replacing Rare Earth Materials in Motor Design: What Are the Key Considerations? 

In this insightful interview, Krishna MPK Namburi, System Controls Engineering Manager at Nexteer Automotive, discusses the transition from rare earth materials to more sustainable and cost-effective alternatives in motor design. With his extensive background in electrical engineering and ongoing research, Krishna offers valuable perspectives on the future of motor technology. Download the PDF to explore the key discussions and insights shared in this interview.

In this interview, Krishna MPK Namburi addresses the following key topics:

• Performance and Efficiency Comparisons: The differences in performance and efficiency between traditional motor designs using rare earth materials and new technologies or materials that avoid these elements. Specific examples and case studies highlight where alternative materials have demonstrated comparable or superior performance.
• Cost Implications: The primary cost implications when transitioning from rare earth materials to alternative options. Discussion includes potential hidden or long-term costs, such as initial investments in research and development, manufacturing adjustments, and increased maintenance costs.
• Design Innovations: Specific design details and innovations in developing alternative materials and magnets. This includes advancements in motor design, such as improved electromagnetic structures, advanced cooling techniques, and optimized control systems.
• Potential of Alternative Materials: The potential of wound synchronous machines and ferrite magnets as replacements for permanent magnet synchronous motors (PMSMs). Specific applications and industries where these alternatives show promise, particularly in automotive and other critical sectors.
• Control System Complexity: The complexity of control systems when using non-rare earth materials in motor design. Technical challenges in implementing control systems for these motors and strategies to overcome them, including advanced temperature monitoring and compensation techniques.
• Manufacturing Processes: The manufacturing process for motors based on non-rare earth materials. Significant differences in manufacturing techniques compared to traditional methods and the adjustments required to optimize magnetic and mechanical performance.

Key Insights to Download:

• Performance and Efficiency: Compare results between traditional motor designs and new technologies/materials that trade-off rare earth materials.
• Cost Considerations: Understand the costs associated with transitioning to alternative materials.
• Design Innovations: Learn about successful design details for alternative materials and magnets.
• Alternative Materials Potential: Examine the potential of wound synchronous machines or ferrite magnets as replacements for PMSMs.
• Control System Challenges: Explore the complexity of control systems using non-rare earth materials.
• Manufacturing Processes: Discover what the manufacturing process looks like for a non-rare earth-based motor.

Download the PDF interview with Krishna MPK Namburi now to uncover valuable insights and strategies for leveraging alternative materials in motor design, ensuring sustainable and cost-effective solutions for the future.

During the interview, Peng Peng, a researcher specializing in Electric Machines and Drive Systems as well as Propulsion Systems at General Motors, shares valuable insights into the essential factors to consider when developing an e-motor strategy. The primary objectives are to enhance performance, increase efficiency, and minimize costs.

Peng also delves into the exploration of innovative concepts and technologies, such as the utilization of new materials, to optimize motor performance while simultaneously reducing expenses. Additionally, Peng underscores the significance of fluctuating raw material prices in the context of cost reduction. He suggests various approaches to reduce material usage and achieve cost savings in the industry. Ultimately, Peng emphasizes the criticality of carefully evaluating machine performance, supply chain dynamics, system-level cost considerations, and operating conditions in the pursuit of minimizing material consumption.

The e-motor industry is currently in a position where organizations are looking to integrate power electronics, the e-motor, and the gearbox, to simplify the system. To do so, many factors need to be included and taken into consideration, such as:

• Designing the components together from the start of the design process.
• Finding the best approach to designing power electronics, the e-motor, and the gearbox together.
• Learning how to improve the efficiency of the motor and inverter system to best complement each other.
• Strategizing the specific steps to take to get the best results from measurements and testing of the final product.

Wanting to find out more, Automotive IQ spoke with Dr. Vineetha Ravindran, Technical Project Lead – Next Generation Inverters at Scania Group, to find out everything there is to know about this integration process.

Discussion highlights:

• Challenges in integrating power electronics, the e-motor, and the gearbox.
• Strategies to overcome integration challenges.
• Techniques for system-level design and integrated approach.
• Methodologies to design power electronics, the e-motor, and the gearbox together.
• Balancing efficiency between e-motors and inverters.
• Common pitfalls in designing e-motor systems and how to avoid them.
• Specific steps in testing the final product.
• Key takeaways for professionals on system-level design for e-motor technologies.
• Success stories and tangible benefits of integrated e-motor system design at Scania Group.
  

PROGRESS IN POWER ELECTRONICS & INVERTER DEVELOPMENT: Presentation by Simon Hart, Honorary Associate Professor in Power Conversion for Electrical Transportation, University of Nottingham.

The inverter is an important part of the EDU/EPU and has specific thermal management needs. The industry is showing growing interest in technologies that decrease loss and that increase the effectiveness of thermal management, both within the inverter and as part of an integrated EDU/EPU system.

• Learn about the developments in power electronics, inverters, and inverter technology

• Learn about innovate cooling technologies for inverter power electronics

• Learn about the benefits of considering motors and inverters as a single, integrated item rather than as separate items at the strategic level