Periodic Reporting for period 2 - eMONIC (The Next Generation of Automotive Electric Motor)
Berichtszeitraum: 2023-07-01 bis 2024-12-31
In response to the rising need for efficient, cost-effective, and sustainable electric motors, particularly in the automotive sector, SciMo has developed an innovative winding technology. This addresses critical challenges in motor design—material efficiency, power density, and cost—driven by the global shift toward electric vehicles (EVs) and the phasing out of internal combustion engines.
Key Features:
- 60% higher copper density
- 90% higher cooling efficiency
- 75% higher power density
- 75% higher material efficiency
- 30% price advantage
Proven in over 70 prototypes for aerospace and motorsports, SciMo now focuses on mid-series volume markets (500–1,000 units/year), targeting electric aviation, motorsports, electric buses, electric off-highway vehicles, and the premium automotive segment.
Impact Pathway:
- Economic: Captures a growing EV market via a B2B model.
- Environmental: Significantly increases the material efficiency of steel, aluminum, neodymium mangnets, and copper, supporting a sustainable mobility.
Hence, SciMo accelerates the transition to greener technologies, aligning with EU sustainability goals. A pilot production line will demonstrate scalability, attracting investors and driving significant impact.
Key Features:
- 60% higher copper density
- 90% higher cooling efficiency
- 75% higher power density
- 75% higher material efficiency
- 30% price advantage
Proven in over 70 prototypes for aerospace and motorsports, SciMo now focuses on mid-series volume markets (500–1,000 units/year), targeting electric aviation, motorsports, electric buses, electric off-highway vehicles, and the premium automotive segment.
Impact Pathway:
- Economic: Captures a growing EV market via a B2B model.
- Environmental: Significantly increases the material efficiency of steel, aluminum, neodymium mangnets, and copper, supporting a sustainable mobility.
Hence, SciMo accelerates the transition to greener technologies, aligning with EU sustainability goals. A pilot production line will demonstrate scalability, attracting investors and driving significant impact.
The SciMo project advanced winding technology for high-performance electric motors through four work packages. It began by assembling a team of software and hardware experts to build a winding machine demonstrator. Regular meetings set weekly goals, and thorough documentation met funding requirements, ensuring a solid foundation for technical progress.
The motor technology was validated in motorsports with a lead customer. Offering 75% higher power density and material efficiency, the motors powered vehicles to win a major U.S. hill climb race and set an Australian track record, proving their value for demanding applications.
Central to the project was the development of a fully automated winding machine demonstrator (WM04).Upgrades included steel plates for rigidity, wire tension increased to over 500N, a pneumatic fixation system handling 650N, and grippers with 150N force. The software was revamped to leverage ROS2, enabling precise control of multiple actuators and two UR16.e robots, while true parallel planning accelerated the process. After additional process refinements, the machine was commissioned in February 2024, and successfully produced a first fully automated coil on a stator. At the end of 2024 winding costs of around 450€ per unit were archieved enabling an annual production volumes of 500–1,000 motors.
To ensure motor reliability, the project implemented a comprehensive quality management system. The MTC2 R7 Schleich motor tester was integrated to assess stators, performing surge voltage, partial discharge, resistance, and insulation resistance tests customized to specific designs. An End-of-Line test bench standardized final motor evaluations, checking magnetic flux, rotation direction, harmonics, and mechanical performance before shipment. Four development test benches allowed flexible testing under diverse conditions—like subzero temperatures and various cooling media—meeting specific customer requirements. In motorsports, testing with the lead customer spanned 500–1,000 km per motor, with only two early prototype failures among 50 drive sets, confirming durability. Aviation testing progressed toward flight clearance for a turbine-coupled generator, paving the way for future certifications such as ISO 9100 and IATF 16949, ensuring consistent quality and market readiness.
SciMo’s robotic automation matched manual precision, with software enabling flexible stator production and single-tooling for all phases. Delivering lighter motors with 75% better efficiency, it set a new standard for motorsports, aerospace, and industrial applications.
The motor technology was validated in motorsports with a lead customer. Offering 75% higher power density and material efficiency, the motors powered vehicles to win a major U.S. hill climb race and set an Australian track record, proving their value for demanding applications.
Central to the project was the development of a fully automated winding machine demonstrator (WM04).Upgrades included steel plates for rigidity, wire tension increased to over 500N, a pneumatic fixation system handling 650N, and grippers with 150N force. The software was revamped to leverage ROS2, enabling precise control of multiple actuators and two UR16.e robots, while true parallel planning accelerated the process. After additional process refinements, the machine was commissioned in February 2024, and successfully produced a first fully automated coil on a stator. At the end of 2024 winding costs of around 450€ per unit were archieved enabling an annual production volumes of 500–1,000 motors.
To ensure motor reliability, the project implemented a comprehensive quality management system. The MTC2 R7 Schleich motor tester was integrated to assess stators, performing surge voltage, partial discharge, resistance, and insulation resistance tests customized to specific designs. An End-of-Line test bench standardized final motor evaluations, checking magnetic flux, rotation direction, harmonics, and mechanical performance before shipment. Four development test benches allowed flexible testing under diverse conditions—like subzero temperatures and various cooling media—meeting specific customer requirements. In motorsports, testing with the lead customer spanned 500–1,000 km per motor, with only two early prototype failures among 50 drive sets, confirming durability. Aviation testing progressed toward flight clearance for a turbine-coupled generator, paving the way for future certifications such as ISO 9100 and IATF 16949, ensuring consistent quality and market readiness.
SciMo’s robotic automation matched manual precision, with software enabling flexible stator production and single-tooling for all phases. Delivering lighter motors with 75% better efficiency, it set a new standard for motorsports, aerospace, and industrial applications.
Key Results
The WM04, a fully automated winding machine developed from the WM03 prototype, delivers significant advancements:
Automation: Fully automated winding process.
- Efficiency: Manual interventions reduced from 13 to 0.3 per hour.
- Production Speed: ROS2 software and parallel planning enable precise, simultaneous control of actuators and robots, accelerating production.
- Cost Reduction: Winding costs lowered to 450€ per unit, viable for 500–1,000 motors annually.
- Versatility: Supports stators with diameters of 100–250mm, lengths of 100–200mm, and 4–20 pole pairs.
Potential Impacts
SciMo’s technology enables lighter, more efficient motors with 75% higher power density, impacting:
Motorsports & Aerospace: Proven for high-performance, demanding applications.
- Industrial Sectors: Scalable and cost-effective for broader use.
- Sustainability: Supports energy-efficient solutions and reduced emissions.
Key Needs for Further Uptake and Success
To ensure success, the following are critical:
- Testing & Validation: Extensive real-world hardware testing.
- Market & Finance Access: Investment and market strategies for commercialization.
- IPR Support: Secure patents to protect technology and attract investors.
- Regulatory Framework: Align with standards for market entry in regulated sectors.
- R&D: Further development to reduce winding costs and expand production capacity.
The SciMo project’s WM04 machine advances electric motor manufacturing with improved efficiency, cost reduction, and performance, validated through testing and motorsports applications. It offers a scalable solution for high-performance motors, with potential to revolutionize production and support sustainability. Continued development and support are key to its future success.
The WM04, a fully automated winding machine developed from the WM03 prototype, delivers significant advancements:
Automation: Fully automated winding process.
- Efficiency: Manual interventions reduced from 13 to 0.3 per hour.
- Production Speed: ROS2 software and parallel planning enable precise, simultaneous control of actuators and robots, accelerating production.
- Cost Reduction: Winding costs lowered to 450€ per unit, viable for 500–1,000 motors annually.
- Versatility: Supports stators with diameters of 100–250mm, lengths of 100–200mm, and 4–20 pole pairs.
Potential Impacts
SciMo’s technology enables lighter, more efficient motors with 75% higher power density, impacting:
Motorsports & Aerospace: Proven for high-performance, demanding applications.
- Industrial Sectors: Scalable and cost-effective for broader use.
- Sustainability: Supports energy-efficient solutions and reduced emissions.
Key Needs for Further Uptake and Success
To ensure success, the following are critical:
- Testing & Validation: Extensive real-world hardware testing.
- Market & Finance Access: Investment and market strategies for commercialization.
- IPR Support: Secure patents to protect technology and attract investors.
- Regulatory Framework: Align with standards for market entry in regulated sectors.
- R&D: Further development to reduce winding costs and expand production capacity.
The SciMo project’s WM04 machine advances electric motor manufacturing with improved efficiency, cost reduction, and performance, validated through testing and motorsports applications. It offers a scalable solution for high-performance motors, with potential to revolutionize production and support sustainability. Continued development and support are key to its future success.