CORDIS provides links to public deliverables and publications of HORIZON projects.
Links to deliverables and publications from FP7 projects, as well as links to some specific result types such as dataset and software, are dynamically retrieved from OpenAIRE .
Deliverables
A new DC 12V electric motor, based on an armature obtained by high pressure moulding of optimised soft iron powder composites (SMC), was designed with respect to environmental and economic criteria.
A formulation containing insulated iron particles and lubricant was processed on an industrial scale. The dependence of manufacturing parameters (compacting pressure, heat treatment, etc.) in relation to mechanical and magnetic properties has been evaluated.
The standard deviation within a batch, and batch-to-batch intervals, has been established for each property. A compromise between Transverse Rupture Strength (TRS) and total magnetic losses was found in accordance with processability of the parts and good motor performance.
Several topologies of motors have been evaluated, especially in the domain of brushless motors with outer rotor. However, due to a higher market demand, the project focused on a 310W DC brush motor.
Finite element calculation software was used in electro-magnetic and mechanical fields in order to define the SMC armature shape. As a result of this study, a complex 3D shape armature was designed in order to catch maximum magnetic flux.
Several problems have been met in carrying out the manufacture of the armatures. This is a result of the complicated shape of the tooling. The complications arise from several sources, the large number of core-rods, and the 3D shape at the end of the teeth being the most important. Hundreds of motors have been produced with no major process modification on a series line. All the endurance tests were passed without any failure. These new motors fulfil the initial objectives of the project:
-Armature thickness is reduced by 11%.
-Armature weight is reduced by 20%.
-Overall motor efficiency is maintained.
Parallel with the motor design, a life cycle analysis was performed on the new armature in order to quantify the environmental performance of the new motor compared to the laminated one. It shows that the improvement of the environmental performance is in the disposal stage due to better copper recovery.
This new technology has been proposed to car manufacturers. A high interest has been shown, especially if this is generalised to all the motors in the car. Diversification studies have shown that other potential applications of this technology exist, essentially in household appliances.
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