Improve efficiency of electric vehicles – Rectangular wire winding

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Electric Motor Efficiency

A rectangular wire winding has been used instead of traditional round wire windings. This would improve efficiency along with power density.

Research and development activities have been conducted across the world to develop electric motors that offer exceptional performance and power. Market players have focused on utilizing a novel approach of a rectangular wire winding around stator instead of traditional round wire winding. In addition, different materials have been found to reduce the overall weight of the motor. These innovations would transform the performance of electric vehicles and bring a new dimension to the market.

Reduction of weight of an electric vehicle is dependent upon the weight of the motor. Utilization of fiber-reinforced polymer materials is one of the ways to achieve. Researchers at the Fraunhofer Institute for Chemical Technology (ICT) have collaborated with researchers at the Karlsruhe Institute of Technology (KIT) for development of a cooling concept in which polymers can be used in motors as housing materials. This cooling concept also enhances efficiency and power density. The researchers have been working on the development of a novel approach in which direct cooling of rotor and stator is involved. There are a static stator and a rotating rotor that have a copper winding through which electricity flows. Majority of copper losses occur in the rotor. However, the new approach lies in utilizing stator. Instead of winding a round wire on the stator, researchers have used rectangular flat wire to wind tightly to the stator.

In this novel design, heat losses are dissipated in the cooling channel inside the stator. The need to transfer the heat to the exterior cooling sleeve is eliminated. Moreover, there are various benefits such as low thermal inertia and high continuous output from the motor. In a new design, there is a rotor cooling solution to allow heat loss of the rotor to be dissipated in a motor only. As the heat is dissipated where it is generated, researchers were able to build the motor and housing with the help of polymer materials. There were certain advantages associated with polymer housing such as lightweight and ease in production.

Electric Motor EfficiencyA major European commercial vehicle producer has chosen BorgWarner’s High Voltage Hairpin (HVH) 410 electric motor for its upcoming hybrid vehicle. The electric motor has become a crucial component for various vehicles such as urban, night-delivery trucks, and others. BorgWarner’s HVH generates 1,050 Nm of torque and 130 kW (174 hp) of power. It will work in a parallel manner with an inline five-cylinder engine running on the hydrotreated vegetable oil (HVO) or diesel. Moreover, HVH charges the battery during downhill coasting and braking. An innovative technique has been used by BorgWarner’s HVH410 electric motors. A rectangular wire winding has been used instead of traditional round wire windings. This would improve efficiency along with power density.

Dr. Stefan Demmerle, President and General Manager, BorgWarner PowerDrive Systems, outlined that the chosen electric motor for plug-in hybrid application will become a game-changer in urban distribution trucks and deliveries during night-time. It utilizes the HVH410 technology on hybrid buses and helps vehicle manufacturers meet industry demands along with enabling efficient operation in noise sensitive areas and zero-emissions zones. The utilization of innovative motors is expected to transform the European market in the coming years. According to the research firm Allied Market Research, the Europe electric motor market is expected to reach $22.32 billion by 2022. The innovations would bring new opportunities in the market in the next few years.

About the Author

Pratik Kirve PhotoPratik Kirve is writer, blogger, and sport enthusiast. He holds a bachelor’s degree in Electronics and Telecommunication Engineering and currently working as a Content Writer at Allied Analytics LLP. He has avid interest in writing news articles across different verticals. When he is not following updates and trends, he spends his time reading, writing poetry, and playing football. (contact via LinkedIn)

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