Optimisation of manufacturing processes and Soft Magnetic Composite (SMC) materials for a new generation of low cost, high efficiency hybrid electric motors

Much effort is being made worldwide to reduce the environmental footprint of motor vehicles, particularly through the development and deployment of electric vehicles (EVs). Improved performance, reliability, safety and cost reduction are the main benefits sought. In Canada, NRC has just completed a project supported by Natural Resources Canada (NRCan) to reduce the cost of electric motors by combining the manufacturing technology expertise of NRC, TM4 and Rio Tinto Metal Powder (RTMP). This project led to TM4 launching 3 new motors in June 2016. By substituting up to 25% of the permanent magnets with soft magnetic composite materials (CMDs), and taking advantage of the reluctance torque of TM4's outer rotor design, motors offering up to 45% increase in torque and speed have been developed. The basis for these new products is the development of an experimental grade of CMD material as part of this project. During the scale-up phase for industrial production, difficulties were encountered that require optimisation of the basic powder properties and the manufacturing process. The objective of this new project is to optimise for this specific application the manufacturing processes and properties required of the CMD materials and to set the specifications of the commercial RTMP product for the mass production of TM4 components. The optimisation paths and recommendations that will be derived from this study will enable RTMP to develop a guide for the optimal use of CMD products for its customers and TM4 to deploy CMD technology across its products.

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