利用增材制造技术重塑下一代电机

Drive13 Accelerating E-Motor InnovationsReshaping Next-Gen E-Motors with Additive Manufacturing Technology CTI Symposium Berlin 3-4 Dec. 2024, Speaker1 2 About Us Our DNA Accelerating E-Motor Innovations SustainableMaterials are a key enabler for the Ourmission is to accelerate the transition tosustainable,power-dense,copper-freeelectricmachinesby bridging the gap between cutting-edgeinnovationandindustrialreadiness. ThermalManagement(e.g. Cooling Jacket) (e.g. Alnico) Our Technology Edge Green Manufacturing >> Durable Solutions >> Sustainable Materials >> Smart use of 3D printing & aluminium Better way of cooling and coating Strategic use of rare earth elements ▪Shape First, Coat After▪No bending or tooling▪Longer endurance▪Advanced cooling solutions for ▪More degree of design freedom▪Better manufacturability▪Short lead time▪Aluminium is lighter and cheaper ▪Sustainable / recyclable material▪Top-end performance for demandingapplications GreenManufacturing Smart use of 3D printing & aluminium Improved EM performance Shape-profiled Hybrid coil High fill coil Optimizationof conductor shape •Perfectfitintrapezoidalshapeslot•Highfillfactor•Lowerlosses•Improvedthermalperformance Thesemi-strandedAlucoilprovides30%lowerlossesat1kHzinaddition Hairpinwindings Watch video Sustainable Materials Windings Challenges with Tooled Copper Windings ▪Expensive Tooling▪Difficult to customize▪High frequency eddy current losses. 15Why Aluminum? Highest power density of high-frequency motors Our motors achieve market-leading power density in high-frequency applications, enabled by optimized designs and the Aluminium outcompetescopper in high frequency CTI Symposium Berlin 2-3 Dec. 2025, Ahmed Selema, Drrive13 Strong Magnet is not always the best magnet ▪Ny is the champion Magnet only at roomtemperature ▪Trade-off between over 80 grades Thermal Thermal management Direct Cooling Channels Hollow coil 2x Current, Half weight Twice Current, Half weight Electrical Insulation Challenge ▪Limited thermal performance of the commercialinsulation materials ▪Bending causes tension on the insulation Conventionaltooled Coil Electrical Insulation ▪Insulation is applieddirectly on the final barecoil, meaning no toolingneeded afterward. ▪Temperature resistance260°C ▪Excellent electricinsulation with no partialdischarges.▪Very good edge coverage Electrical Insulation ▪Controllable film thicknessof 25 μm–200 μm ▪Unmatched chemical No Partial discharge @ extreme conditions 20kHz at 70ns rise time Case Studies: Racing Motor ▪PMSM for Racing Motor Outcome ▪Innovative integration in closed slot stators▪no forming or bending▪>80% Slot fill factor▪>35% Stator weight reduction▪Higher reliability for demanding HighAltitudecoils High Altitude coils Design:Axial Flux Motor High Altitude coils Electrical insulation Material ReducedPD activity and higherinceptionvoltages ▪At 30,000 feet,the breakdownvoltageof air is roughly 30-40%lowerthanatsealevel. ▪AtDrive13,weensurehigh-qualityinsulationmaterialwithvoids-free Move fromConventionaltoExceptional Ahmed Selema,PhD CTO–drive13selema@drive13.tech www.drive13.tech Accelerating E-Motor Innovations