EV POWER TRAINS

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​            AXIAL FLUX MOTORS

                                                       

  1. POWER TRAIN

  2. DRIVE TRAIN                                                               

  3. FULL VEHICLE DEVELOPMENT                                                                          

  4. 3 D MODELLING

  5. MOULD DESIGN

  6. ELECTRIC ENGINES

  7. AXIAL FLUX MOTOR MANUFACTURING

  8. COMPLETE SOLID AXLE SOLUTIONS

  9. MOTOR CONTROLLER DESIGN & MFG.

  10. ODB II  CAN BUS PROFIBUS 
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Axial-Flux Motors and Generators

Shrink Size, Weight

The yokeless, permanent-magnet topology offers greater efficiency around the motor’s central axis, and wastes very little copper on windings because the motors have zero overhang.

Moving Past Induction Motors and Gearboxes

Electric machine solutions are currently dominated by combinations of standard induction motors and gearboxes. These induction motors have a typical maximum efficiency below 90% at full load, and lower at partial loads. They also often produce long, massive drive trains.

Newer machine concepts use permanent magnets to generate a constant magnetic field and thus generate a flux by design. As a result, the power density and dynamic performance of PM machines is higher than induction or electrically excited machines, where the magnetic field must be created (directly or indirectly) via an electrical current.

Radial-flux (RF) direct-drive (DD) machines are an alternative solution to overcome the efficiency and reliability issues of traditional solutions associated primarily with gearboxes. DD machines eliminate the gearbox and connect the generator or motor coupled directly to the load. For this solution to be effective, the motor/generator must be able to supply the required drive torque directly, and at low speed, which requires an entirely new motor/generator design.

RF DD machines are heavier and more expensive due to the use of radial magnetic flux to transfer power. Fundamental electromagnetic and thermal constraints with this approach result in machines that are often both wide and long, compared with state-of-the-art models.

AXIAL FLUX MOTOR DESIGN

EV MOTOR MANUFACTURING LINE

STATORS

ROTORS

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EOL

      Test procedure is based on the motor’s voltage and current.

·          Test procedure measures all of the motor characteristics, from stall up to no load speed, in just a few seconds.

·          NO loading of the motor is necessary.

·          NO sensor is required for DCPM motors.

·          COMPLETE test performance in just a few seconds of running the motor.  

·          Performs QA testing on 100% of production, without compromising line throughput (up to 10 motors per minute), reducing costs of defective products.     

·          Determines acceptability to user predefined PASS/FAIL limits on production lines.

·          Detects electrical and mechanical defects according

This focuses on the steps to compare methods to detects faults at the end of line (EOL) testing section after the assembly of permanent magnet synchronous motors (PMSM) for automotive, especially truck applications. In detail two philosophies were discovered in case of using end of line test benches to check all functionalities of an electric motor after all assembly steps. The comparison is a practical approach and involves three parts to investigate on the passive end of line test bench as a sufficient method to detect all critical faults and the performance of PMSMs.

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