Magneti | ATE | AQ

Speeding up

eco-technology.

In Italy, Magneti Marelli, a key designer and supplier of components to the world’s automakers, has selected Hi-Lite as a critical element in its new high-performance electric motor for supercars.

An international Group committed to the design and production of hi-tech systems and components for the automotive sector, Magneti Marelli supplies most key car manufacturers in Europe, North and South America and Asia. In 2010, the Group received a very special commission – to develop and manufacture the power electronics and electric motor for a highly exclusive hybrid supercar.

Vincenzo Giorgianni, who heads Electromagnetic Design at Magneti Marelli’s Hybrid & Electric Systems Division, explains the requirement and challenges.

“This electric motor must deliver considerable torque at very low speeds, requiring a high magnetic flux between rotor and stator. But it must deliver high power at high speeds too, to provide powerful acceleration at speeds over 200 km/h with no loss of efficiency. This means magnetic losses must be kept low, even at very high rotation speeds. A motor able to perform at high rotation speeds can generate the specified power output in a more compact design than one performing at lower rotation speeds, offering a clear space gain.

High Torque

Hybrid

The final choice fell on a customised Hi-Lite 0.27 mm grade resulting in 30% lower losses at high rotation speeds compared to the best available 0.35 mm grades, in combination with a higher mechanical strength which engenders a 6% gain of torque compared to standard grades. The final result is an electric motor with the maximum speed of 16 000 rpm, 165 horsepower, which combined with the V12 combustion engine delivers an impressive 1000 horsepower.

ATE – Accelerating

motor demands.

Germany’s ATE (AntriebsTechnik und Entwicklungs) GmbH, which designs and produces high-speed electric motors for automotive, aerospace and medical applications, relies on Hi-Lite for its low energy loss at high frequencies, its high saturation and its cost efficiency.

“We are seeing growing market demand for higher-speed motors,” explains Herbert Sutter, CEO of German manufacturer ATE Antriebstechnik und Entwicklungs GmbH, who is directly responsible for Sales & Projects at the company. “Higher speed means higher efficiency. Our main product line is high-speed motors for a broad range of applications. There is no exact definition for a high-speed motor, but we consider any that operate at a frequency of several hundred Hz or higher to be high-speed. Our largest market is the machine tool industry (high-speed spindles).”

Automotive applications fuel growth

Herbert Sutter comments on the automotive industry’s particularly sharp growth in interest for high-speed machines. “We manufacture a range of products for the automotive sector and participate in several development projects. Our electric drives for turbo chargers are just one good example, where rotational speeds of up to 200 krpm are attracting keen interest. Other key application areas for high-speed motors are found in the aircraft industry and medical technology. Energy is another segment in which we are active, where we are engaged in developing a micro turbine generator for inclusion in a combined heat-and-power unit for family homes.”

Cutting costs

with higher prices.

AQ Trafo, a major Global manufacturer of inductive components, has chosen Hi-Lite for its high-performance products.

Designed in Sweden and manufactured at its plants in Bulgaria, China and India, AQ Trafo produces inductive components for some of the most demanding applications – high-speed trains, relay protection systems, military equipment, aircraft and process-automation equipment. Increasingly, the company is turning to Hi-Lite grades for its high-performance components. Christer Eriksson, Senior Engineer, explains why.

“The main reason is advances in solid-state power electronics. There has been a significant increase in the switching frequencies of converters (used to control the speed of electric motors), allowing components to be made smaller and lighter. Higher switching frequencies generate high-frequency harmonics, negatively affecting both the electric motor and other devices connected to the grid. One such effect is increased energy loss.”

Size and weight matter
“An inductor is often fitted to filter unwanted harmonics before they affect the motor or spread on the grid – but the harmonics causes losses in the core of the inductor/filter. We now use Hi-Lite grades to reduce such losses to acceptable levels. Losses in the core can make it too hot and a bigger core would be impractical for the traction applications that are our main focus. A bigger and heavier filter would cancel out the benefits of a smaller and lighter converter. Employing Hi-Lite instead of more conventional electrical steel grades for high-frequency applications (typically 2-20 kHz) allows us to design more compact cores with smaller and lighter converters.”

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