In the mobility sector, if you want to be optimally positioned for the future you need to develop sustainable solutions as quickly as possible. This applies not only to the manufacture of drive systems and their components, but also to their use on roads, rail, water or in the air.
By using Soft Magnetic Composites (SMC) we are already meeting this challenge, thus laying today’s foundations for the mobility of tomorrow.
The advantages of this material come into their own right from the start, during the production stage of the components for the CONNACTIVE eDrive. In conventional systems the stator, for example, is usually manufactured from electric steel sheets which have to be punched, stacked and then, in most cases, bonded together at high temperatures.
In the SMC version, the metal powder is pressed into a corresponding die and then heated briefly. The insulation layer of the individual particles is inorganic and is therefore completely preserved.
MINIMAL WASTE, LOWER COSTS
By pressing the complete component in one piece, no waste occurs during stator production. The advantage: as less material is used, valuable resources are saved. At the same time there are no “scraps” that need to be re-melted, something which would require additional heat and thus energy input.
A further advantage of this material: each individual metal particle in the SMC powder is pre-treated with a special surface coating (1) providing particularly high electrical resistance. This means that the necessary electrical insulation layer is applied three-dimensionally and thinner than the layers applied by conventional methods. Even without further production stages the eddy current losses during high-frequency operation are minimal.
A NEW SOLUTION FOR NEW MARKETS
Together with the lower weight and space-saving design of the overall system, this makes the CONNACTIVE eDrive the perfect drive for compact e-solutions: in urban transport, for example. Especially in the Asian market, urban e-mobility is already playing an important role, but in Europe, too, the demand is steadily growing – and will grow increasingly rapidly over the coming years.
And of course, today’s standard drive systems are not the only area of application for SMC: it also offers enormous opportunities for efficiency and performance in other types such as hub motors for mobility scooters, for example.
This makes SMC the material of the future.
SUSTAINABLE FURTHER USAGE
Admittedly, even the production of components from Soft Magnetic Composites doesn’t come without thermal reactions. But here, too, our partners Höganäs have thought ahead and found a sustainable use for the residual heat generated. Instead of releasing it unused via the cooling towers, they simply feed it into the Swedish district heating grid.
ENERGY FOR THE REGION
In this way, over one thousand households in the southern Swedish province of Skåne are supplied with energy and warm water, and in addition resources are saved and carbon emissions reduced.
VP Automotive Business Development, Vishay
„In future electric motors will be the key driving force behind a new, innovative automotive market. Not only through the new and further development of electric drive units or hybrid systems, but also for the peripherals.“