Motor rotor achieves weight reduction of 40% Alvant aluminum matrix composites, which also reduces manufacturing costs
Innovate UK's “MakeitLighterwithLess” (lighter with less material) project development competition found that engineers looking for significant improvements in motor efficiency and performance can benefit from aluminum-based composites (AMC).
According to foreign media reports, Innovate UK's “MakeitLighterwithLess” (lighter with less material) project development competition found that engineers looking for significant improvements in motor efficiency and performance can benefit from aluminum-based composites (AMC).
Metal matrix composites are metal materials reinforced with high performance auxiliary materials. Generally, the auxiliary material is in the form of long fibers, short fibers or granules.
The project was carried out by the British aluminum-based composites specialist Alvant and GEAviation, YASAMotors and the National CompositesCenter, achieving 40% weight reduction on the rotor of the axial flux machine. At the same time, the power inertia ratio of the rotor is increased. In addition, the number of assembly lines is reduced, which reduces assembly time.
As the electrification trend develops, automakers are demanding ways to optimize motor efficiency. For example, by increasing the efficiency of torque and speed, the energy consumption of the vehicle is ultimately determined. The industry faces the challenge of identifying ways to improve efficiency and performance while simplifying manufacturing and reducing total cost.
Alvant's proprietary aluminum-based composites allow components to be precisely optimized for strength-to-weight ratios and rugged weight ratios when needed. Alvant's proprietary Advanced Hydroforming (ALPF) method can selectively enhance a portion of the assembly using one of the performance materials in a near net shape manufacturing process. Alternatively, Alvant's materials can be applied to the assembly as discrete inserts for cost savings.
By using an aluminum-based composite in the rotor, Alvant reduces weight in axial flux motor applications. The reduced weight of the part means that it can be streamlined, and engineers can reduce the number of fixing bolts required and reduce material usage and assembly time.
Although the innovative UK/YASA project focuses on passenger car rotors, Alvant's own research projects demonstrate the use of aluminum-based composites in high-stress or high-temperature applications such as aerospace, automotive, defense, consumer goods and sports equipment. The results that can be achieved.
