New permanent magnet motor topologies using advanced magnetic materials

The project aims to develop new electric motor topologies using advanced magnetic materials and manufacturing techniques. The project will identify, simulate, build and optimise innovative motor topologies by taking advantage of 3D magnetic flux design. The 3D magnetic flux designs will be made possible by the simultaneous development of soft and hard magnetic materials and their manufacturing process. Firstly, the compaction of soft magnetic composites offers unique isotropic magnetic properties compared to the laminates that are typically used for the manufacture of stators. Secondly, cold spray additive manufacturing of hard magnetic materials allows the manufacture of permanent magnets with complex 3D geometries that cannot be achieved on rotors using traditional manufacturing methods. Both technologies also offer manufacturing advantages such as a reduction in the number of components and assembly steps, thereby reducing the cost of the electric motor. The end result is to achieve, by the end of the project, the manufacture of low cost, high performance electric motors that target the requirements of an automotive application.

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