These 4 technologies could revolutionize the electric motors industry.
1) Die-cast copper rotors:
– Induction motors use Aluminium die-cast rotors which are less conductive than copper
– Aluminium melting temperature is 660 deg.C vs 1083 deb.C for copper was unworkable for traditional die-casting induction motors
-Due to the advancements in the development of die-casting materials that can withstand higher temperatures, leading to the availability of copper die-casted rotors for induction motors
-Copper die-casted rotors can have lesser energy losses by 12 to 15%.
2) Square wire winding:
– Using square copper wires in its rotors, eliminating the gaps that are inherent in winding round wires.
– This increases the slot fill factor and maximises the copper, which means improving the air-gap flux density and positively impacting the torque and power.
– Tighter, more compact rotor windings should generate more torque in less space, and a rotor with fewer soldering points promises a longer lifespan and lower production costs
3) Trapezoidal radial flux:
– Trapezoidal toothed rotors give higher torque in a smaller package than competing radial motor designs
– Prototypes of the trapezoidal radial flux motor deliver more power and suffer less heat loss than the brushless DC motors used in most electric vehicles
4) Anodised Aluminium foil winding: recently published a post on this. You can check further details in that post
– Aluminium oxide electrical insulation has a high thermal conductivity
– Aluminium has already been used for a long time as a conductor in electric machines due to their attractive properties
– Aluminium is almost 3 times lighter than copper, has lower price volatility, better recyclability and lower impact on the environment as compared to copper
These technologies are in the initial stage of research and would need to mature to have mass production and yet with Cost-effectiveness.
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