FEMM Hub Present at E-motor Tech, Berlin

Dr Alexei Winter and Dr Jill Miscandlon presented at E-motor Tech which took place in Berlin between September 29 – October 01.

Alexei's presentation was titled 'Novel Technologies for E-Motors' describing several novel technologies that are under investigation at the University of Sheffield’s Advanced Manufacturing Research Centre (AMRC). The focus is on developing and translating innovative technologies from the lab towards industrial adoption. The talk will cover several recently completed projects in the field of electrification, such as the formation of hollow conductor coils for direct cooling, wet winding of coils with high-viscosity encapsulants, additive manufacturing to reduce weight and increase power density, and robotic placement of large permanent magnet arrays for wind turbine generators.

Planned future work and upcoming capability expansions were discussed on:

• Formation of 4 mm x 4 mm hollow conductors into complex coil shapes for direct conductor cooling

• Pre-encapsulating multi-strand coils during the winding process with high-viscosity encapsulants

• Additive manufacturing for lightweight: reducing weight and increasing power density

• A robotic solution for the placement of large, magnetized permanent magnet arrays for a wind turbine generator

Jill presented two sessions:

 Circular Design and Manufacturing of E-Motors for a More Sustainable Future   

'The key focus in the realm of e-motors lies at the intersection of lightweight design, optimized manufacturing, and cost savings, with an emphasis on retaining value through circular processes. By crafting e-motors with lightweight materials and streamlined construction, their energy efficiency through life is optimized. Furthermore, through efficient remanufacturing processes and a commitment to secondary applications, these e-motors are afforded a second life, significantly reducing waste, and preserving valuable resources. In this circular economy approach, sustainability is paramount, and the motors can be designed to maintain their performance while minimizing environmental impact.'

The presentation delved into:

• Optimizing manufacture through lightweight design

• Sustainability through remanufacturing and secondary applications

• Circular economy for sustainable motors

What are the best paths to a future of fully sustainable E-motors?

The discussion included:

• Where does recycling sit on the circular economy hierarchy?

• Where do e-motor design strategies currently stand with circularity in mind?

• How can we ensure every part of the motor is optimally processed after its first life cycle?

• Can we achieve fully circular e-motors?

• What barriers are in the way of this?