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ReFreeDrive 03 - Webinar induction motor advanced manufacturing

- The document describes the hairpin winding manufacturing process for electric motors used in electric vehicles. It involves cutting wire to length, forming hairpins, winding assembly including inserting the windings into the stator slots, and quality checks. Key steps discussed in more detail include wire cutting, hairpin forming using different technologies, and the winding design process which aims to optimize performance and costs.

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16 Dec 2020 1 This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 770143 1 This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 770143 16 Dec 2020 Rare earth free e-drives featuring low manufacturing cost European Copper Institute Aurubis Breuckmann e-Mobility Tecnomatic Webinar #3: Induction motors for e-mobility - advanced manufacturing features
16 Dec 2020 2 This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 770143 ReFreeDrive Project Overview 13 partners, 6 European countries OEM Validation Project coordination Power electronics Vehicle integration & testing Copper Steel Motor Design & Manufacturing
16 Dec 2020 3 This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 770143 ReFreeDrive Project Overview Why rare earth elements free solutions? Environment & LCA CostSupply risk Market uncertainties
16 Dec 2020 4 This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 770143 ReFreeDrive Project Overview • The main aim of this project is to develop rare earth‐free traction technologies Project Objectives INDUSTRIAL FEASIBILITY MASS PRODUCTION LOWER COSTS • Material selection • Manufacturing processes • Design optimisation • Scalability
16 Dec 2020 5 This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 770143 ReFreeDrive Project Overview ProjectTechnologies: we will design & manufacture 8 different e-motors for electrical powertrains Induction machines with copper rotor Fabricated Die Cast Synchronous reluctance machines PMassisted Without PM 75kW and 200kW 8 motors
16 Dec 2020 6 This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 770143 ReFreeDrive Project Overview Target figures 30% INCREASE SPECIFIC TORQUE 50% MOTOR LOSSES REDUCTION 15% COST REDUCTION 50% INCREASE OF POWER DENSITY IN POWER ELECTRONICS
16 Dec 2020 7 This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 770143 ReFreeDrive Project Overview Please visit: www.refreedrive.eu and ElectricDrivetrainInnovationCluster in LinkedIn
European Commission Grant Agreement No770143 Fabricated copper rotor Denise Willems – Aurubis Belgium
Alloys – Cu vs CuAg 200 250 300 350 400 450 500 550 600 20 50 100 150 175 200 250 300 325 350 400 500 550 UTS(N/mm²) Temperature (°C) Annealing Curves Cu CuAg0,002 CuAg0,005 CuAg0,01 CuAg0,05 CuAg0,1 CuAg0,4 CuAg0,7 CuAg1
Portfolio Aurubis Specialities provides a wide range of copper segments from simple to complex designs Standard Dimensional Range
Recycling Casting Casting Plastic Deformation Production Process – Cu Parts Cu+ACP Electrolysis Ag 200E/T 400E/T Cold Reduction Cut to Length De-burring 400E/T 200E/T 200E/T Casting 200E/T Rolling 400E/T Punching 400E/T 0,098kg/Piece 0,69E/Piece (0,54/0,15) 0,553kg/Piece 3,65E/Piece (3,05/0,6)
Production Process – Squirrel Cage Assembly Lamination Stack XXX E/Assy Rotor x50 34,44E/Assy End Ring x2 7,31E/Assy Bearings x2 XXX E/Assy Assembly + Soldering 18,5 E/Assy Shaft XXX E/Assy Balancing 1,5 E/Assy IM Inner Rotor Cost 61,75 Euros (excluding steel parts)
AC-Motors 6 Aurubis Bars & Profiles provides constant product quality and cut to lengths Thank you for your attention
High Performance Cast Rotors with Zero Porosity David Schmitz Technical Director breuckmann eMobility
2 Agenda 1. Introduction 2. Basics of Casting Technology 3. Zero Porosity Rotor (ZPR®) Casting Technology 4. Advantages of ZPR®
3 Breuckmann Group Business Areas Casting Technology Core Competencies 1. Tool Design 2. Tool Manufacture 3. Die Casting > 1000°C 4. CNC Post-Processing Hungary Kft. TECH Center Poland Key Facts 5 Locations in Europe Annual Turnover > 25 mio. € > 200 Employees > 120 Years Business Activity Headquarters Operations
4 Rotor Examples AluminiumCopper
5 Milestones in Rotor Casting OEM – USA 2016 TIER1 – USA 2018OEM – DE 2015 R 0,52 mm R 0,38 mmR 0,61 mm Open and closed slots
6 Mnufacturing of High Performance Rotors Packaging • Stacking and fixing of laminations onto a mandrel Preaheating • Preheating the lamiation stack Casting • Rotor casting Removing mandrel • Removal of mandrel from cast rotor Lamination delivery Rotor Casting • Melting temperature • Tool temperature • Melt treatment • Gating system • Piston velocity • Venting Post processing • Machining, shaft insertion, balancing Ready for assembly in the motor
7 Basics of Casting Technology 2nd Phase 3rd Phase Reflection of a jam wave 𝒗 𝒌 < 𝒗 𝒌𝒓𝒊𝒕 Over shock wave 𝒗 𝒌 > 𝒗 𝒌𝒓𝒊𝒕 Perfect 1st phase 𝒗 𝒌 = 𝒗 𝒌𝒓𝒊𝒕 Die 1st Phase
8 Current Status of the Industry Standard high pressure casting with turbulent filling Enclosed air
9 Laminar Squeeze Casting (LSC) Breuckmann´s Laminar Filling Venting
10 Zero Porosity Rotor - CT Analysis Side A 0% Porosity Side B 0% Porosity
11 Zero Porosity Rotor - Advantages Superior mechanical characteristics + 12,5 % max. rpm Maximum Process Stability Higher Electrical Conductivity
Rotation Moves Us All Thank you very much
2 SUMMARY - Hairpin Winding Manufacturing process - Hairpin Winding design criteria +39 0861 839030 www.tecnomatic.it m.vetuschi@tecnomatic.it Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
3 OVERVIEW OF PROCESS STEPS Wire Cut to length Hairpin Forming Winding Assembly Winding Insertion Insertion into stack Slot liner Forming Free-ends Twisting Winding Welding Quality Checks CROWN ASSEMBLY FINAL ASSEMBLYINSERTION INTO THE STACK HAIRPIN FORMING SLOT LINER INSERTION Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
4 WINDING DESIGN TRADE-OFF CRITERIA CODESIGN The codisegn approach was adopted during the design of the Induction Motor for the Re Free Drive project held by the project partner Motor Design Limited, maximizing motor performance by designing the stator lamination and the winding as a whole: Winding Specs Review Definition of Winding schemes and Winding-Ends dimensions Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
5 WINDING DESIGN TRADE-OFF CRITERIA Winding Specs Review Calculation of Winding Losses & Verification of Insulation Specs Definition of Winding schemes and Winding-Ends dimensions Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A. CODESIGN The codisegn approach was adopted during the design of the Induction Motor for the Re Free Drive project held by the project partner Motor Design Limited, maximizing motor performance by designing the stator lamination and the winding as a whole:
6 WINDING DESIGN TRADE-OFF CRITERIA 3D modelling Winding Specs Review Calculation of Winding Losses & Verification of Insulation Specs Definition of Winding schemes and Winding-Ends dimensions Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A. N.2 N.4 N. 8 flat wires per slot CODESIGN The codisegn approach was adopted during the design of the Induction Motor for the Re Free Drive project held by the project partner Motor Design Limited, maximizing motor performance by designing the stator lamination and the winding as a whole:
7 WINDING DESIGN TRADE-OFF CRITERIA CODESIGN Maximizing motor performance by designing the stator lamination and the winding as a whole: N.2 Process Design Performance/Cost Front N.43D modelling Winding Specs Review Calculation of Winding Losses & Verification of Insulation Specs Definition of Winding schemes and Winding-Ends dimensions Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved N. 8 flat wires per slot Max speed = 18 krpmBase Speed = 8 krpm Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A. Large improvement from 2 to 4 layers Lower improvements @ 6/8 layers @ speed<base
8 KEY PROCESS STEPS WIRE CUT TO LENGTH Wire Cut to length Hairpin Forming Winding Assembly Winding Insertion Insertion into stack Slot liner Forming Free- ends Twisting Winding Welding Quality Checks Includes 1. Enamel stripping 2. Free-ends preparation for welding 3. Wire cut For different wire lengths, automatically varying. Standard Mid-path Phase terminals Slot exit Potentially, corrections can be performed on the fly. Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
9 KEY PROCESS STEPS Wire Cut to length Hairpin Forming Winding Assembly Winding Insertion Insertion into stack Slot liner Forming Free- ends Twisting Winding Welding Quality Checks HAIRPIN FORMING Different forming technologies can be applied, according to the product specifications and cycle time. PLANAR BENDING (2D) CIRCUMF. BENDING (3D) SEPARATED OR INTEGRATED BENDING OPERATIONS Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
10 KEY PROCESS STEPS Wire Cut to length Hairpin Forming Winding Assembly Winding Insertion Insertion into stack Slot liner Forming Free- ends Twisting Winding Welding Quality Checks WINDING ASSEMBLY CROWN ASSEMBLY CROWN COMPLETION WINDING ASSEMBLY Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
11 KEY PROCESS STEPS Wire Cut to length Hairpin Forming Winding Assembly Winding Insertion Insertion into stack Slot liner Forming Free- ends Twisting Winding Welding Quality Checks FREE-END TWISTING Pocket matrices bend the hairpin legs, moving their ends of a predetermined distance in • Circumferential direction • Radial direction matching the Insulation Resin application Process and the Product Requirements. CW CCW TWISTING POCKETS RADIAL WIDENING CLEARANCE BETWEEN WELDED PAIRS Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
12 KEY PROCESS STEPS Wire Cut to length Hairpin Forming Winding Assembly Winding Insertion Insertion into stack Slot liner Forming Free- ends Twisting Winding Welding Quality Checks WINDING WELDING Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic uses Trumpf Sources for Laser Welding Welding templates are used to accurately displace the pairs to be welded and to protect the insulation coating. Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
13 KEY PROCESS STEPS Wire Cut to length Hairpin Forming Winding Assembly Winding Insertion Insertion into stack Slot liner Forming Free- ends Twisting Winding Welding Quality Checks QUALITY CHECKS Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A. Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
14 Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved The winding scheme is reviewed, to reduce the process complexity and preserve motor efficiency and robustness. Winding and motor should be designed as a whole with manufacturability constraints (CODESIGN) Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A. PRODUCT-PROCESS TRADE-OFF CRITERIA
15 PRODUCT-PROCESS TRADE-OFF CRITERIA layer 1 layer 2 layer 3 layer 4 mid-core CUT VIEW of SLOT EMBEDDED PHASE CONDUCTORS MULTIPLE PHASE SEPARATORS in SLOT SINGLE PHASE SEPARATOR in SLOT Process Features Simplification of twisting process Simplification of slot-liner and winding insertion into the stator core Product Features Shorter winding-end Larger copper to slot filling factor Slot insulation Slot insulation Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved The winding scheme is reviewed, to reduce the process complexity and preserve motor efficiency and robustness. Winding and motor should be designed as a whole with manufacturability constraints (CODESIGN) Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
16 Insertion side Twisted side Hairpin 3 Hairpin 1 Hairpin 2Hairpin 4 Hairpin 3 Hairpin 1 Hairpin 2I-pin1I-pin2 INVERTER CONNECTIONS at TWISTED SIDE ROLLED OUT STATOR VIEW INVERTER CONNECTIONS at INSERTION SIDE Hairpin 4 substituted by two I-pins Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A. PRODUCT-PROCESS TRADE-OFF CRITERIA
17 WINDING DESIGN TRADE-OFF CRITERIA Insertion side Twisted side ROLLED OUT STATOR VIEW Possibly shorter winding-endsProduct Features Bus-bar is required Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A. Hairpin 3 Hairpin 1 Hairpin 2Hairpin 4 Hairpin 3 Hairpin 1 Hairpin 2I-pin1I-pin2 INVERTER CONNECTIONS at TWISTED SIDE INVERTER CONNECTIONS at INSERTION SIDE
18 Insertion side Twisted side ROLLED OUT STATOR VIEW Process Features Minimum number of shape variants Simplification of twisting process Simplification of assembly process Simplification of welded-pairs encapsulation process at twisting side. Possibly shorter winding-endsProduct Features Bus-bar is required Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A. Hairpin 3 Hairpin 1 Hairpin 2Hairpin 4 Hairpin 3 Hairpin 1 Hairpin 2I-pin1I-pin2 INVERTER CONNECTIONS at TWISTED SIDE INVERTER CONNECTIONS at INSERTION SIDE PRODUCT-PROCESS TRADE-OFF CRITERIA
19 Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A. Balance of paths: Berardi, Grazia, and Nicola Bianchi. "Design guideline of an AC hairpin winding." 2018 XIII International Conference on Electrical Machines (ICEM). IEEE, 2018. Bianchi, Nicola, and Grazia Berardi. "Analytical Approach to Design Hairpin Windings in High Performance Electric Vehicle Motors." 2018 IEEE Energy Conversion Congress and Exposition (ECCE). IEEE, 2018. PRODUCT-PROCESS TRADE-OFF CRITERIA PRODUCT WINDING FEATURES PROCESS FEATURES Efficiency (ac resistance) Heat dissipation Torque density Suitability for mass production Number of layers Number of parallel paths Slot filling factor Geometry and clearances of the Winding- ends N. of segment length variants N. of hairpin shape variants Interleaved or independent crowns N. of welds N. of jumpers Slot liner geometry
20 CONCLUSIONS - Outline of the process steps for the IM winding of the ReFreeDrive project - Design criteria for winding specs of ReFreeDrive project with Performance to Cost target Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
THANK YOU FOR THE ATTENTION +39 0861 839030 www.tecnomatic.it m.vetuschi@tecnomatic.it

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ReFreeDrive 03 - Webinar induction motor advanced manufacturing

  • 1.
    16 Dec 20201 This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 770143 1 This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 770143 16 Dec 2020 Rare earth free e-drives featuring low manufacturing cost European Copper Institute Aurubis Breuckmann e-Mobility Tecnomatic Webinar #3: Induction motors for e-mobility - advanced manufacturing features
  • 2.
    16 Dec 20202 This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 770143 ReFreeDrive Project Overview 13 partners, 6 European countries OEM Validation Project coordination Power electronics Vehicle integration & testing Copper Steel Motor Design & Manufacturing
  • 3.
    16 Dec 20203 This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 770143 ReFreeDrive Project Overview Why rare earth elements free solutions? Environment & LCA CostSupply risk Market uncertainties
  • 4.
    16 Dec 20204 This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 770143 ReFreeDrive Project Overview • The main aim of this project is to develop rare earth‐free traction technologies Project Objectives INDUSTRIAL FEASIBILITY MASS PRODUCTION LOWER COSTS • Material selection • Manufacturing processes • Design optimisation • Scalability
  • 5.
    16 Dec 20205 This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 770143 ReFreeDrive Project Overview ProjectTechnologies: we will design & manufacture 8 different e-motors for electrical powertrains Induction machines with copper rotor Fabricated Die Cast Synchronous reluctance machines PMassisted Without PM 75kW and 200kW 8 motors
  • 6.
    16 Dec 20206 This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 770143 ReFreeDrive Project Overview Target figures 30% INCREASE SPECIFIC TORQUE 50% MOTOR LOSSES REDUCTION 15% COST REDUCTION 50% INCREASE OF POWER DENSITY IN POWER ELECTRONICS
  • 7.
    16 Dec 20207 This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 770143 ReFreeDrive Project Overview Please visit: www.refreedrive.eu and ElectricDrivetrainInnovationCluster in LinkedIn
  • 8.
    European Commission Grant AgreementNo770143 Fabricated copper rotor Denise Willems – Aurubis Belgium
  • 9.
    Alloys – Cuvs CuAg 200 250 300 350 400 450 500 550 600 20 50 100 150 175 200 250 300 325 350 400 500 550 UTS(N/mm²) Temperature (°C) Annealing Curves Cu CuAg0,002 CuAg0,005 CuAg0,01 CuAg0,05 CuAg0,1 CuAg0,4 CuAg0,7 CuAg1
  • 10.
    Portfolio Aurubis Specialities providesa wide range of copper segments from simple to complex designs Standard Dimensional Range
  • 11.
    Recycling Casting CastingPlastic Deformation Production Process – Cu Parts Cu+ACP Electrolysis Ag 200E/T 400E/T Cold Reduction Cut to Length De-burring 400E/T 200E/T 200E/T Casting 200E/T Rolling 400E/T Punching 400E/T 0,098kg/Piece 0,69E/Piece (0,54/0,15) 0,553kg/Piece 3,65E/Piece (3,05/0,6)
  • 12.
    Production Process –Squirrel Cage Assembly Lamination Stack XXX E/Assy Rotor x50 34,44E/Assy End Ring x2 7,31E/Assy Bearings x2 XXX E/Assy Assembly + Soldering 18,5 E/Assy Shaft XXX E/Assy Balancing 1,5 E/Assy IM Inner Rotor Cost 61,75 Euros (excluding steel parts)
  • 13.
    AC-Motors 6 Aurubis Bars &Profiles provides constant product quality and cut to lengths Thank you for your attention
  • 14.
    High Performance CastRotors with Zero Porosity David Schmitz Technical Director breuckmann eMobility
  • 15.
    2 Agenda 1. Introduction 2. Basicsof Casting Technology 3. Zero Porosity Rotor (ZPR®) Casting Technology 4. Advantages of ZPR®
  • 16.
    3 Breuckmann Group Business Areas CastingTechnology Core Competencies 1. Tool Design 2. Tool Manufacture 3. Die Casting > 1000°C 4. CNC Post-Processing Hungary Kft. TECH Center Poland Key Facts 5 Locations in Europe Annual Turnover > 25 mio. € > 200 Employees > 120 Years Business Activity Headquarters Operations
  • 17.
  • 18.
    5 Milestones in RotorCasting OEM – USA 2016 TIER1 – USA 2018OEM – DE 2015 R 0,52 mm R 0,38 mmR 0,61 mm Open and closed slots
  • 19.
    6 Mnufacturing of High PerformanceRotors Packaging • Stacking and fixing of laminations onto a mandrel Preaheating • Preheating the lamiation stack Casting • Rotor casting Removing mandrel • Removal of mandrel from cast rotor Lamination delivery Rotor Casting • Melting temperature • Tool temperature • Melt treatment • Gating system • Piston velocity • Venting Post processing • Machining, shaft insertion, balancing Ready for assembly in the motor
  • 20.
    7 Basics of CastingTechnology 2nd Phase 3rd Phase Reflection of a jam wave 𝒗 𝒌 < 𝒗 𝒌𝒓𝒊𝒕 Over shock wave 𝒗 𝒌 > 𝒗 𝒌𝒓𝒊𝒕 Perfect 1st phase 𝒗 𝒌 = 𝒗 𝒌𝒓𝒊𝒕 Die 1st Phase
  • 21.
    8 Current Status ofthe Industry Standard high pressure casting with turbulent filling Enclosed air
  • 22.
    9 Laminar Squeeze Casting(LSC) Breuckmann´s Laminar Filling Venting
  • 23.
    10 Zero Porosity Rotor- CT Analysis Side A 0% Porosity Side B 0% Porosity
  • 24.
    11 Zero Porosity Rotor- Advantages Superior mechanical characteristics + 12,5 % max. rpm Maximum Process Stability Higher Electrical Conductivity
  • 25.
    Rotation Moves UsAll Thank you very much
  • 27.
    2 SUMMARY - Hairpin WindingManufacturing process - Hairpin Winding design criteria +39 0861 839030 www.tecnomatic.it m.vetuschi@tecnomatic.it Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
  • 28.
    3 OVERVIEW OF PROCESSSTEPS Wire Cut to length Hairpin Forming Winding Assembly Winding Insertion Insertion into stack Slot liner Forming Free-ends Twisting Winding Welding Quality Checks CROWN ASSEMBLY FINAL ASSEMBLYINSERTION INTO THE STACK HAIRPIN FORMING SLOT LINER INSERTION Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
  • 29.
    4 WINDING DESIGN TRADE-OFFCRITERIA CODESIGN The codisegn approach was adopted during the design of the Induction Motor for the Re Free Drive project held by the project partner Motor Design Limited, maximizing motor performance by designing the stator lamination and the winding as a whole: Winding Specs Review Definition of Winding schemes and Winding-Ends dimensions Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
  • 30.
    5 WINDING DESIGN TRADE-OFFCRITERIA Winding Specs Review Calculation of Winding Losses & Verification of Insulation Specs Definition of Winding schemes and Winding-Ends dimensions Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A. CODESIGN The codisegn approach was adopted during the design of the Induction Motor for the Re Free Drive project held by the project partner Motor Design Limited, maximizing motor performance by designing the stator lamination and the winding as a whole:
  • 31.
    6 WINDING DESIGN TRADE-OFFCRITERIA 3D modelling Winding Specs Review Calculation of Winding Losses & Verification of Insulation Specs Definition of Winding schemes and Winding-Ends dimensions Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A. N.2 N.4 N. 8 flat wires per slot CODESIGN The codisegn approach was adopted during the design of the Induction Motor for the Re Free Drive project held by the project partner Motor Design Limited, maximizing motor performance by designing the stator lamination and the winding as a whole:
  • 32.
    7 WINDING DESIGN TRADE-OFFCRITERIA CODESIGN Maximizing motor performance by designing the stator lamination and the winding as a whole: N.2 Process Design Performance/Cost Front N.43D modelling Winding Specs Review Calculation of Winding Losses & Verification of Insulation Specs Definition of Winding schemes and Winding-Ends dimensions Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved N. 8 flat wires per slot Max speed = 18 krpmBase Speed = 8 krpm Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A. Large improvement from 2 to 4 layers Lower improvements @ 6/8 layers @ speed<base
  • 33.
    8 KEY PROCESS STEPS WIRECUT TO LENGTH Wire Cut to length Hairpin Forming Winding Assembly Winding Insertion Insertion into stack Slot liner Forming Free- ends Twisting Winding Welding Quality Checks Includes 1. Enamel stripping 2. Free-ends preparation for welding 3. Wire cut For different wire lengths, automatically varying. Standard Mid-path Phase terminals Slot exit Potentially, corrections can be performed on the fly. Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
  • 34.
    9 KEY PROCESS STEPS WireCut to length Hairpin Forming Winding Assembly Winding Insertion Insertion into stack Slot liner Forming Free- ends Twisting Winding Welding Quality Checks HAIRPIN FORMING Different forming technologies can be applied, according to the product specifications and cycle time. PLANAR BENDING (2D) CIRCUMF. BENDING (3D) SEPARATED OR INTEGRATED BENDING OPERATIONS Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
  • 35.
    10 KEY PROCESS STEPS WireCut to length Hairpin Forming Winding Assembly Winding Insertion Insertion into stack Slot liner Forming Free- ends Twisting Winding Welding Quality Checks WINDING ASSEMBLY CROWN ASSEMBLY CROWN COMPLETION WINDING ASSEMBLY Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
  • 36.
    11 KEY PROCESS STEPS WireCut to length Hairpin Forming Winding Assembly Winding Insertion Insertion into stack Slot liner Forming Free- ends Twisting Winding Welding Quality Checks FREE-END TWISTING Pocket matrices bend the hairpin legs, moving their ends of a predetermined distance in • Circumferential direction • Radial direction matching the Insulation Resin application Process and the Product Requirements. CW CCW TWISTING POCKETS RADIAL WIDENING CLEARANCE BETWEEN WELDED PAIRS Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
  • 37.
    12 KEY PROCESS STEPS WireCut to length Hairpin Forming Winding Assembly Winding Insertion Insertion into stack Slot liner Forming Free- ends Twisting Winding Welding Quality Checks WINDING WELDING Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic uses Trumpf Sources for Laser Welding Welding templates are used to accurately displace the pairs to be welded and to protect the insulation coating. Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
  • 38.
    13 KEY PROCESS STEPS WireCut to length Hairpin Forming Winding Assembly Winding Insertion Insertion into stack Slot liner Forming Free- ends Twisting Winding Welding Quality Checks QUALITY CHECKS Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A. Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
  • 39.
    14 Copyright © 2020Tecnomatic S.p.A. All Rights Reserved The winding scheme is reviewed, to reduce the process complexity and preserve motor efficiency and robustness. Winding and motor should be designed as a whole with manufacturability constraints (CODESIGN) Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A. PRODUCT-PROCESS TRADE-OFF CRITERIA
  • 40.
    15 PRODUCT-PROCESS TRADE-OFF CRITERIA layer1 layer 2 layer 3 layer 4 mid-core CUT VIEW of SLOT EMBEDDED PHASE CONDUCTORS MULTIPLE PHASE SEPARATORS in SLOT SINGLE PHASE SEPARATOR in SLOT Process Features Simplification of twisting process Simplification of slot-liner and winding insertion into the stator core Product Features Shorter winding-end Larger copper to slot filling factor Slot insulation Slot insulation Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved The winding scheme is reviewed, to reduce the process complexity and preserve motor efficiency and robustness. Winding and motor should be designed as a whole with manufacturability constraints (CODESIGN) Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
  • 41.
    16 Insertion side Twisted side Hairpin3 Hairpin 1 Hairpin 2Hairpin 4 Hairpin 3 Hairpin 1 Hairpin 2I-pin1I-pin2 INVERTER CONNECTIONS at TWISTED SIDE ROLLED OUT STATOR VIEW INVERTER CONNECTIONS at INSERTION SIDE Hairpin 4 substituted by two I-pins Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A. PRODUCT-PROCESS TRADE-OFF CRITERIA
  • 42.
    17 WINDING DESIGN TRADE-OFFCRITERIA Insertion side Twisted side ROLLED OUT STATOR VIEW Possibly shorter winding-endsProduct Features Bus-bar is required Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A. Hairpin 3 Hairpin 1 Hairpin 2Hairpin 4 Hairpin 3 Hairpin 1 Hairpin 2I-pin1I-pin2 INVERTER CONNECTIONS at TWISTED SIDE INVERTER CONNECTIONS at INSERTION SIDE
  • 43.
    18 Insertion side Twisted side ROLLEDOUT STATOR VIEW Process Features Minimum number of shape variants Simplification of twisting process Simplification of assembly process Simplification of welded-pairs encapsulation process at twisting side. Possibly shorter winding-endsProduct Features Bus-bar is required Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A. Hairpin 3 Hairpin 1 Hairpin 2Hairpin 4 Hairpin 3 Hairpin 1 Hairpin 2I-pin1I-pin2 INVERTER CONNECTIONS at TWISTED SIDE INVERTER CONNECTIONS at INSERTION SIDE PRODUCT-PROCESS TRADE-OFF CRITERIA
  • 44.
    19 Copyright © 2020Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A. Balance of paths: Berardi, Grazia, and Nicola Bianchi. "Design guideline of an AC hairpin winding." 2018 XIII International Conference on Electrical Machines (ICEM). IEEE, 2018. Bianchi, Nicola, and Grazia Berardi. "Analytical Approach to Design Hairpin Windings in High Performance Electric Vehicle Motors." 2018 IEEE Energy Conversion Congress and Exposition (ECCE). IEEE, 2018. PRODUCT-PROCESS TRADE-OFF CRITERIA PRODUCT WINDING FEATURES PROCESS FEATURES Efficiency (ac resistance) Heat dissipation Torque density Suitability for mass production Number of layers Number of parallel paths Slot filling factor Geometry and clearances of the Winding- ends N. of segment length variants N. of hairpin shape variants Interleaved or independent crowns N. of welds N. of jumpers Slot liner geometry
  • 45.
    20 CONCLUSIONS - Outline ofthe process steps for the IM winding of the ReFreeDrive project - Design criteria for winding specs of ReFreeDrive project with Performance to Cost target Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied, described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified, distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
  • 46.
    THANK YOU FORTHE ATTENTION +39 0861 839030 www.tecnomatic.it m.vetuschi@tecnomatic.it