Production Of Electric Motors Research Articles

Microstructural and textural evolution of double stage cold rolled non-grain oriented electrical steel

Non-grain oriented electrical steels (NGOES) are typically used in electric applications with rotating magnetic fields and thus essential for the production of electric motors. The increasing number of electric vehicles results in a growing demand for electrical steel sheets used in the stacked laminations of rotor and stator components. E-mobility applications require the best possible magnetic properties for optimum performance and efficiency, especially at high frequencies. In addition, increased mechanical strength is necessary to withstand the centrifugal forces resulting from high revolution speeds. Chemical composition, microstructure and crystallographic texture strongly influence the magnetic properties, whereas the mechanical properties are mainly affected by the chemical composition and grain size. Optimizing the texture is a possible method for improving the magnetic properties without significantly compromising the mechanical strength. In this work a special processing route for the production of 3.25% Si NGOES sample material has been studied, using laboratory cold rolling and annealing facilities. Compared to the classical processing route of single stage cold rolling and annealing, this alternative method involves two cold rolling steps with an intermediate annealing treatment between the first and second rolling sequence and a final annealing treatment after the second rolling step. The samples were produced with different intermediate thicknesses, changing the amount of cold rolling deformation of each sample variation. The degree of deformation affects the recrystallization and grain growth behavior and thus the resulting microstructure and texture. The microstructural and textural evolution was investigated in the hot rolled, intermediate annealed and final annealed state using electron backscatter diffraction (EBSD). Finished samples were additionally examined using magnetic testing and tensile testing. The results indicate a correlation between the intermediate thickness and the final grain size of the steel samples. Furthermore, the highly grain size dependent mechanical strength and magnetic losses are influenced. EBSD-data were used to interpret the texture and to calculate a parameter describing the magnetic quality of the texture. The results show a strong improvement of magnetically favorable texture components along with increasing intermediate thickness, enabling significantly better polarization values in rolling direction and transversal direction. However, anisotropy of the magnetic properties increases as well due to the textural changes.

Model-based closed-loop process control for the manufacturing of hairpin coils

As a consequence of the increasing market share of hybrid and all-electric mobility solutions, there is a need for robust manufacturing technologies that enable the efficient production of powerful electric traction motors in automotive industry. In the context of high-quality distributed stator windings, the so-called hairpin technology already meets the automotive demand regarding productivity – but process reliability is still limited by variations in the mechanical and geometric properties of the enameled rectangular copper wire leading to different springback effects within the forming processes. Against this background, a model-based closed-loop process control for the sequential tool-bound bending of hairpin coils is introduced and validated in this paper.

Additively manufactured vacuum grippers for the flexible handling and assembly of hairpin coils in electric motor production

Hairpin technology has recently become the predominant winding technology for the manufacturing of stators used in electric traction motors. In contrast to conventional winding techniques, the manufacturing process chain is based on rectangular wire which is bent into a three-dimensional U-shape – so-called hairpin coils. These hairpin coils have to be individually gripped and assembled to form the stator winding. There can be hundreds of hairpin coils in a single stator, which can also differ in shape. Therefore, gripping and moving the individual hairpin coils is a challenging task in terms of flexibility and cycle time. This paper presents an approach to meet the outlined requirements using additively manufactured vacuum grippers. A concept is investigated in which the vacuum is generated in a conventional vacuum ejector and fed to the vacuum gripper via hose lines. In contrast, the concept of a functionally integrated vacuum gripper manufactured by a new laser-sintering process with automated continuous fibre reinforcement is presented. Based on the laser-sintering process, a lightweight vacuum gripper with an integrated vacuum ejector can be manufactured in a single process step without additional costs for purchased parts. After a review of the state of the art in both hairpin-specific and additively manufactured lightweight grippers, experimental test series are carried out concerning the vacuum quality and the grip strength of the different vacuum gripper designs. Pull-off tests show that high holding forces of several Newtons are possible proving the basic usability of vacuum grippers for hairpins, even though the achievable vacuum quality of the functionally integrated vacuum gripper is lower than that of the conventional ejector. Comparison of the novel approaches with a conventional mechanical hairpin gripper regarding weight, production costs and production time show promising improvements.

TRACTION ALTERNATOR FOR ELECTRIC DRIVE OF FRONT LOADER CHASSIS

For heavy construction equipment with a hybrid electric transmission, the power center of a group of traction electric drives can be formed by an electric generator and a renewable energy storage device (battery array) with the possibility of their joint operation to provide a surge of current in a group of traction electric drives. The battery array can be used to power a generator in a starter mode when starting a diesel internal combustion engine.
 
 The purpose of the study is to substantiate the choice of the magnetic system of the power generator for the electric transmission and the possibility of a starter mode for an internal combustion engine drive. The study was carried out within the framework of a subsidized project to create mass production of a family of front loaders with a hybrid electric drive in Chuvashia.
 
 Materials and research methods. The studies were carried out by the method of finite element analysis using the Russian software ELCUT (professional version and a set of reference books for domestic electrical and magnetic materials).
 
 Results. The stage of analytical calculation of the active parts of a transmission electric generator for the preliminary design stage is presented. It was carried out for the following conditions: the use of Russian electrical and magnetic materials, the use of common industrial bearings and antifreeze, compatibility with existing technological equipment in the production of traction electric motors, engine mode for performing the starter function. The substantiation of the choice of the magnetic system based on the ratios of magnetic fluxes of different sizes of stator teeth is given. The article is illustrated with diagrams of magnetic and thermal fields for given operational characteristics and properties of a transmission electric generator.
 
 Conclusions. For a given type of drive diesel engines installed on the front loaders, the highest efficiency indicators of the proposed generator magnetic system occur when using a multiplier. The power supply of the generator in the starter mode is provided by the installed array of traction batteries of the front loader without additional step-up converters.

Process Development of Screen-Printed Magnetic Sheets for Electric Machines via Statistical Design of Experiments

Electrical machines play a major role in achieving a more sustainable economy by driving the further electrification of industry and transportation. To enhance the electric motor productivity during production and the efficiency during operation, it is essential to maximize the material yield rate during the production of stator and rotor sheet stacks and reduce iron losses during operation. Screen-printing technology can help to achieve these goals by producing thin magnetic sheet laminations in near-net-shape geometry, resulting in minimum material waste during production. Moreover, reducing the sheet thickness decreases the eddy current losses and avoids mechanical stress during manufacturing, leading to improved motor efficiency. Additionally, screen printing facilitates the production of multi-material components and variable alloy compositions. This study aims to identify the relevant factors and printing parameters so that screen-printed magnetic sheets can achieve product specifications. A method involving the statistical design of experiments is performed in several iterations to investigate the target parameters of the print cycle time, green part weight, shape integrity and layer thickness, and to analyze the main interdependencies. The results of this study provide valuable insights into optimizing the screen-printing process for soft magnetic sheets, enabling the production of efficient electric motors while reducing material scrap.

LIFE CYCLE ASSESSMENT AND CIRCULAR ECONOMY INDICATORS TO DESIGN SUSTAINABLE ELECTRIC OUTBOARDS: RESULTS FROM WORKSHOPS WITH INDUSTRIAL EXPERTS

AbstractTo help industries in their sustainable and circular transition from internal combustion engine production to electric motor production, the deployment of (i) a sound environmental impact assessment methodology, such as life cycle analysis, coupled with (ii) Design for Re-X tools, such as circularity indicators, is instrumental. To demonstrate the industrial relevance and complementary of both approaches, two consecutive workshops are conducted with a major original equipment manufacturer of recreational boats and their associated engines. On this basis, two circularity indicator-based tools were used to quantify and enhance (i) the circularity potential of the electric outboard as a whole, and (ii) the circularity performance of the two most impactful components, based on the LCA results: the electric motor unit and the lithium-ion battery pack. In all, the practice sessions supported the generation of strategic and operational ideas to improve the circularity of the electric outboard. As the industrial participants found both frameworks easy to use and efficient, all the details and resources used to conduct, replicate, or adapt such workshops in other industrial contexts are shared.

Parameters Identification of a Permanent Magnet DC Motor: A Review

Since permanent magnet direct current (DC) motors are mainly used in various industrial automation applications, the demand for electric motors is increasing rapidly. However, in the mass production of electric motors, often, only random inspections are used to check the specifications and performance of electric motors. For manufacturing or engineering application staff to have a more thorough understanding of the characteristics of the motor, it is necessary to conduct a full or quick inspection during the production process to ensure the quality of the electric motor. Based on this, this literature review reveals several methods and algorithms often used to estimate DC motor parameters, given the importance of knowing the parameters of the DC motor and the lack of research on estimating the parameters of the DC motor.

The Concept Of Developing Unmanned Self-Propelled Vehicles

The article discusses conceptual designs for development of unmanned self-propelled wheeled vehicles to study space bodies such as the Mars and the Moon. All previously used designs were conceptually developed in the 1960s on the basis of the Russian space school and have shown them to advantage, although they had some serious drawbacks. At present, when the race to conquer space of the Moon and Mars is underway, where more and more new 'players' are included, the development of self-propelled propellers capable of not only to move, but also to perform very complex research functions for a long period of time seems to be a very difficult and urgent task. A group of scientists carrying out research on the developing of an unmanned self-propelled wheeled vehicle capable of transporting wounded miners from the mines or fighters from the battlefield have developed a fundamentally new conceptual design based on two-wheeled modules connected by a unique coupling device that provides high stability, passability and reliability. Further tests of the developed unmanned self-propelled wheeled vehicle showed that this concept can be successfully used for development of space objects such as the Moon and Mars. Consultations with specialists of industrial organizations of Udmurtia proved the correctness of the conclusions and confirmed the technical possibilities of implementing this project at their production facilities. Considering that the industrial enterprises of the Udmurt Republic have all the necessary competencies in the development of spacecraft control systems, the production of unique electric motors and materials capable of operating in extreme space conditions gives the right to consider the proposed concept as a very promising development that has no analogues in the world and provides technological superiority in the process of exploration of the Moon and Mars.

A Method to Design Assembling Lines for Super Premium Efficiency Motors

Producing highly efficient electric motors remains a challenge nowadays. Given that the legislation in the field requires the transition to the production of engines with increased efficiency, for manufacturing companies, switching from one generation of engines to another can be a difficult task. This paper analyzes ways to adapt the assembly of engines of the IE4 generation starting from the assembly lines of the engines of the previous generation, IE3. The analysis of the assembly process covers both the operator training part and the actual assembly part. Ten possible variants for the assembly line and specific decisional variables have been defined. The decision to choose the optimal assembly configuration was made using as management tools the matrix of consequences and utilities. The validation of the theoretical model of the assembly line was carried out through a case study built for two classes of electric motors, namely G90 and G180. For a total production of IE4 electric motors of 20,000 parts/month, the analyzed variants, respectively, the two sizes (G90 and G100) represent 35% (7000 parts/month) of the G90 size and 22% (4400 parts/month) the G100 size. The aim is to provide a new modular assembly concept, which depending on the orders, can use, as given in the conclusion of this article.

Data-driven quality monitoring of needle winding processes in electric motor production using machine learning techniques

Data-driven quality monitoring of needle winding processes in electric motor production using machine learning techniques

The Russian electric car market: prospects, factors hindering industry development, specifics of component production

The article examines the general course of federal policy in the Russian Federation with regard to the development of the car market in the electric vehicle segment. Government policy should aim to reduce the percentage of vehicles with internal combustion engines (ICE). As of early 2022, projects for the production of electric cars and electric motors are being developed in the Russian Federation and are in the implementation stage. The raw material base in the Russian Federation makes it possible to produce electric vehicles and their components without exporting raw materials. The increase in mineral production is necessary to boost the rate of production of high-tech and innovative products for various industry segments. Trends in the global energy transition are reflected not only in the dynamics of the oil and gas market but also in the development of related industries. They influence the demand for different types of metals and minerals. It is well known that clean technologies require much more metals than their fossil fuel based counterparts. Rare earth metals have now become an integral part of green technology as they are widely used in wind turbine generators, engines for electric vehicles.

Process Segmented based Intelligent Anomaly Detection in Highly Flexible Production Machines under Low Machine Data Availability

Anomaly detection is a key feature to monitor production systems an avoid downtimes, which has still not been implemented holistically. Especially in highly flexible plants or special process machines, conventional approaches like neuronal network classification or intelligent autoencoder fault detection are not suitable firstly due to the small amount and secondly due to the lack of labeling of data for each process. In this paper a novel concept is presented to segment different processes intelligently in the first step to find fine granular process patterns across process boundaries. Based on these patterns, anomaly detection and further classification are performed. A special feature is the integration of user knowledge, so that classification is possible even with a small amount of data. This approach is validated on an assembly line for electric motor production as well as in a handling robot. This paper shows results from real test series and thus demonstrates the practical suitability of the novel approach.

Agile Production Systems for Electric Mobility

Against the background of growing environmental awareness and ambitious international efforts against global warming, sales in the electric mobility sector are expected to rise steadily in the coming years. However, volatile markets accompanied by shorter product life cycles and uncertainties regarding legal, political and technological developments make it still difficult to forecast accurate figures and requirements of components such as batteries or electric motors. Therefore, the investment in highly productive but non-versatile production lines must be seen as a risk. Instead, the tension between need and uncertainty causes a need for rapidly adaptable, profitable production systems with low investment risk. In literature, the term "agile production systems" is often used in this context. Based on an extensive literature review, this paper therefore presents the state of research and attempts to develop a general definition of agile production systems in the context of electric mobility. In particular, relationships to existing production concepts are considered. The practical implementation of agile production systems is described using two different case studies. On the one hand, agile battery cell production based on modular and fully enclosed robotic cells is presented. This approach, based on microenvironments with adjustable humidity, enables a highly automated pouch cell production that is flexible in terms of material, number of units and format. Furthermore, the case study of an agile electric motor production is presented. Process chains of rotor and stator production are analyzed and an approach to conceptualize an agile production system for electric motors is introduced.

Analysis of the Reasons for the Tearing of Strips of High-Strength Electrical Steels in Tandem Cold Rolling.

High-strength non-oriented electro-technical steels with a low thickness possess excellent isotropy of electromagnetic and mechanical properties which is highly required in the production of high-efficiency electric motors. The manufacturing process of this type of steel includes very important and technologically complex routes such as hot rolling, cold rolling, temper rolling, or final heat treatment. The final thickness is responsible for the decrease in eddy-current losses and is effectively achieved during cold rolling by the tandem rolling mill. Industrial production of thin sheets of high-strength silicon steels in high-speed tandem rolling mills is a rather demanding technological operation due to the increased material brittleness that is mainly caused by the intensive solid solution and deformation strengthening processes, making the dislocation motion more complex. The main objective of this work was to investigate the distribution of local mechanical strains through the thickness of high silicon steel hot bands, generated during the cold rolling. The experimental samples were analysed by means of electron back-scattered diffraction and scanning electron microscopy. From the performed analyses, the correlation between the material workability and the nucleation of cracks causing the observed steel strip failure during the tandem cold rolling was characterized. Specifically, the microstructural, textural, misorientation, and fractographic analyses clearly show that the investigated hot band was characterized by a bimodal distribution of ferrite grains and the formation of intergranular cracks took place only between the grains with recrystallized and deformed structures.

Fatigue behaviour of thin Fe-Si steel sheets for electric motor production

The on-going evolution toward electric/hybrid traction requires the development of high-performance electric motors. The rotor of electric motors is made from a stack of thin steel sheets and a complex configuration of magnets. Electric steels are typically Fe-Si alloys where Si addition controls grain size. Mechanical durability assessment of electric motors is based on the fatigue performance of Fe-Si steels.This contribution reports a thorough mechanical characterisation of a Fe-Si alloy in the form of thin (i.e. 0.2 mm) sheets. Numerous tensile tests were performed to characterize the reference static properties and their respective scatter. A suitable fatigue testing procedure for thin sheets was developed and used in an extensive campaign aimed at investigating the directional fatigue behaviour of the Fe-Si steel. Comparison with literature data confirms that the fatigue response of thin sheets is affected by different factors related especially to the method of extraction.

Model improvement through real data connection for Virtual commissioning in ramp-up management of scalable production systems

The electric motor production of the automotive industry faces numerous challenges due to weak sales and uncertain sales forecasts of the electric vehicle. To meet these challenges, scalable production systems have increasingly been set up. The application of virtual commissioning to scalable production systems holds increased potential since the deterministic simulation model can be improved step by step through the inclusion of real data. Therefore, a concrete process model is to be created describing how virtual commissioning can be made even more effective through real data connection. The validation is carried out on an application from material handling technology.

Y. V. Bakumov’s contribution to the development of domestic electrical industry

The aim of the article is to publish the little-known information about the life and professional achievements of domestic organizer of production and designer in the field of electrical engineering Yuriy Bakumov; to reveal some peculiarities of production activity in the electrotechnical industry in the period of the 60’s – 70’s of the 20 th century. Research methods. Historical and biographical methods are applied in the work in the context of consideration the stages of life and assessment of production experience of Y. Bakumov. The use of the interview method yields additional previously unknown information about his life and activities. Main results. The special role of Kharkiv electrotechnical enterprises and the activity of their manufacturers for the development of the electrotechnical industry in Soviet times are emphasized. Kharkiv Electrotechnical Plant was the largest manufacturer of induction motors, generators and electric pumps in Ukraine. Its development began in 1932. One of the developers and organizers of the production of the most famous A4 series engines was Y. V. Bakumov. Y. V. Bakumov’s life was very difficult: his father was repressed, he was in forced labour in Germany. He made his career from a simple locksmith to a chief engineer at the HELZ plant. In this position, Y. V. Bakumov worked for more than ten years. In 1975, Y. V. Bakumov became the CEO of the newly formed Ukrelectromash production association. There is a detailed analysis of the main achievements of the enterprise led by Y. V. Bakumov. The scientific contribution of Y. V. Bakumov in the development of electrical engineering, memories of his personal life and family are presented. Y. V. Bakumov died in 1977, and in 1979 he was posthumously awarded the State Prize of the USSR and the Order of the Red Banner of Labour. Concise conclusions. Y. Bakumov made a significant contribution to the development of the domestic electrical industry. Under his leadership, the reconstruction and technical re-equipment of the production of electric motors were carried out, its efficiency was increased, and new equipment was created and implemented at the enterprises of Ukrelectromash. Nevertheless, the greatest achievement of Yuriy Viktorovich and the whole team of the Production Association are reliable electric motors, which are still successfully operating in various fields. Practical meaning. The formation of historical science should be based on the achievements, discoveries and developments made by individual figures within a certain direction of scientific and technological progress or industry. That is not simply recorded objectively existing results but continue to serve humanity, promoting his civilizational progress. Originality. Scientific research concerning the consideration of personalities and the life path of individuals who contributed to the formation of our country's industries (especially in the Soviet era) is urgent. Equally important is the fact that, until recently, within the national history of science and technology, very little research has been conducted aimed at isolating the wealth of Ukrainians in the development of scientific and technological thought and industrial production in the Soviet period. In our view, replenishment of national historical science with such data will not only serve patriotic goals, but also help to restore justice and give greater objectivity in assessing the role of our compatriots in civilizational progress. Scientific novelty. The topic of formation of the domestic electrotechnical industry and its scientific support in recent years has caused a great scientific interest on the part of domestic scientists. The biography of Y. V. Bakumov will allow to reveal more fully the achievements in the electrical engineering sphere, to rethink its problems, as well as help the development of scientific ideas about the peculiarities and regularities of functioning of the industry as a whole. Article type: historic-biographical.

Testing Emerging EV Technologies

As e-axles and e-mobility technologies develop, new solutions are evolving for the testing of the performance, endurance, and production of electric motors and inverters

Machine Learning in Production – Potentials, Challenges and Exemplary Applications

Recent trends like autonomous driving, natural language processing, service robotics or Industry 4.0 are mainly based on the tremendous progress made in the field of machine learning (ML). The increased data availability coupled with affordable computing power and easy-to-use software tools have laid the foundation for using such algorithms in a wide range of industrial applications, e.g. for predictive maintenance, predictive quality or machine vision. However, a systematic guideline for identifying and implementing economically viable ML use cases in manufacturing industry is still missing. In particular, there is still a lack of a structured overview of concrete, industry-specific best practices that can be easily transferred to one’ s own production. Hence, this paper aims to summarize various existing application scenarios of ML from a process and an industry sector perspective. The process point of view mainly covers the main manufacturing process groups of DIN 8580, handling operations according to VDI 2860 as well as selected cross-process approaches. From an industry sector perspective, application scenarios from various subsectors such as the production of electronics, electric motors, transmission components and medical devices are outlined.

The dynamic improvement methods of energy efficiency and reliability of oil production submersible electric motors

In the organization of production and operation of submersible electric motors (ESP), as the most essential element of electric submersible plants (ESP) in the oil industry, it is necessary to consider specific operating conditions. The submersible electric motors (SEM) as most essential element of electrosubmersible installations (EI) in oil branch accounting of operation specific conditions is necessary in the process production and operation. They are determined by the conditions under which the EPU is operated. They are defined by the EPU operation conditions. For a complete picture the current state of the SED fleet in oil production, the results of its statistical analysis are given. For a comprehensive idea of the SEM park current state the results of statistical analysis are given in oil production. Currently, assessed the performance of submersible equipment produced by major manufacturers. Currently the operational characteristics assessment of the submersible equipment released by the main producers is given. It is stated that standard equipment cannot fully ensure efficient operation with the help of serial EIs, therefore new technologies and corresponding equipment are required to be developed. It is noted that the standard equipment could not provide fully effective operation by means of serial ESP therefore new technologies development and the corresponding equipment are required.