Motor

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Additive Drives uses injection-moulded copper

Additive Drives has developed an injection-moulded copper process for the next generation of electric-drive busbars, writes Nick Flaherty. The development combines the best of two worlds: specialised design and mass production. Additive Drives is using the process for busbars with printed, conventional or injection-moulded parts in copper and plastic.

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ZF offers three-step service with new Bike Eco System

With the market launch of its ZF Bike Eco System, ZF has given details of its three-step service and training concept, which, it says, guarantees minimal effort for manufacturers, dealers and customers when it comes to servicing and retrofitting.

Grid

MW-class motor electric aircraft takes off with 3300 bhp

Wright Electric has finished assembling its second-generation megawatt-class motor, the WM2500, writes Nick Flaherty. The motor has been built with support from the US ARPA-E ASCEND research programme and NASA, and it is spinning freely after being assembled in December.

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Aluminium busbar process cuts costs and weight

brandgroup, a medium-sized, German company, is to develop and manufacture innovative and efficient springs, spring assemblies and wire-forming parts using a process for the manufacturing of aluminium busbars with high-cross sections up to 300 mm2 in the automotive charging path to cut weight and cost, writes Peter Donaldson.

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Schuler automates high-speed blanking with Backlack

Various methods are used to produce stacks of laminations for electric motors from electrical sheets. Schuler has integrated its Backlack technology into a complete, fully automated turnkey system with a high-speed press, as well as stacking and baking stations.

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Equipmake doubles continuous power of heavy-duty motor

Equipmake has unveiled a heavy-duty electric motor with double the continuous power of its predecessor. The HTM-3500 state-of-the-art e-motor boasts the same peak figures of 3500 Nm and 400 kW as before, but continuous power has been doubled from 100 kW to 200 kW at 2500 rpm.

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Powering two- to three-wheelers in Asia

FRIWO has developed a motor control unit and software specifically for two- and three-wheel vehicles in Asia, writes Nick Flaherty. The MC1.5-55A-48V unit has a continuous power output of 1.5 kW for light EVs using permanent magnet synchronous motors (PMSM), making it ideal for electric scooters, motorcycles and other vehicles, particularly in India, Vietnam and Indonesia, and generally in Southeast Asia.

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AZL Aachen invites firms to join rotor sleeves project

AZL Aachen has announced a Joint Partner Project, focusing on the technology for reinforcing electric motors with fibre-composite reinforcement sleeves. The nine-month scheme will investigate current and future applications for electric motors, their requirements for armouring sleeves and provide technological insights.

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Comau unveils end-to-end hairpin stator solutions for e-motor manufacturing

Comau has launched a comprehensive hairpin stator technology portfolio, covering everything in the manufacturing process from hairpin wire forming and insertion to wire widening, twisting, laser welding and quality testing.

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Motor development and manufacturing

Peter Donaldson details the many processes involved in creating new motor systems. As with any sophisticated industrial process, the development of motor systems for e-mobility is a complex and multi-stage endeavour, subject to rapid change under pressure, both to innovate and ramp up to high production volumes.