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ReFreeDrive 03 - Webinar induction motor advanced manufacturing

Recording at: https://youtu.be/06D7Fc4lxSw
In this webinar we present the manufacturing routes of the ReFreeDrive induction motor. Aurubis will present the fabricated copper rotor, Breuckmann e-mobility will present the die-cast copper rotor and Tecnomatic the hairpin winding.

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ReFreeDrive 03 - Webinar induction motor advanced manufacturing

  1. 1. 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
  2. 2. 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
  3. 3. 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
  4. 4. 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
  5. 5. 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
  6. 6. 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
  7. 7. 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
  8. 8. European Commission Grant Agreement No770143 Fabricated copper rotor Denise Willems – Aurubis Belgium
  9. 9. 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
  10. 10. Portfolio Aurubis Specialities provides a wide range of copper segments from simple to complex designs Standard Dimensional Range
  11. 11. 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)
  12. 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. 13. AC-Motors 6 Aurubis Bars & Profiles provides constant product quality and cut to lengths Thank you for your attention
  14. 14. High Performance Cast Rotors with Zero Porosity David Schmitz Technical Director breuckmann eMobility
  15. 15. 2 Agenda 1. Introduction 2. Basics of Casting Technology 3. Zero Porosity Rotor (ZPR®) Casting Technology 4. Advantages of ZPR®
  16. 16. 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
  17. 17. 4 Rotor Examples AluminiumCopper
  18. 18. 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
  19. 19. 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
  20. 20. 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
  21. 21. 8 Current Status of the Industry Standard high pressure casting with turbulent filling Enclosed air
  22. 22. 9 Laminar Squeeze Casting (LSC) Breuckmann´s Laminar Filling Venting
  23. 23. 10 Zero Porosity Rotor - CT Analysis Side A 0% Porosity Side B 0% Porosity
  24. 24. 11 Zero Porosity Rotor - Advantages Superior mechanical characteristics + 12,5 % max. rpm Maximum Process Stability Higher Electrical Conductivity
  25. 25. Rotation Moves Us All Thank you very much
  26. 26. 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.
  27. 27. 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.
  28. 28. 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.
  29. 29. 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:
  30. 30. 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:
  31. 31. 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
  32. 32. 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.
  33. 33. 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.
  34. 34. 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.
  35. 35. 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.
  36. 36. 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.
  37. 37. 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
  38. 38. 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
  39. 39. 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.
  40. 40. 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
  41. 41. 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
  42. 42. 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
  43. 43. 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
  44. 44. 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.
  45. 45. THANK YOU FOR THE ATTENTION +39 0861 839030 www.tecnomatic.it m.vetuschi@tecnomatic.it

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