How will the next generation of motor technology revolutionize materials and architecture?

Time：2024-06-26 Source： Hits：485

In the era of dual-carbon strategy, the new energy vehicle drive motor, as its core component, is ushering in an important stage of development of high efficiency, miniaturization and intelligence. In order to enhance the power density of the drive motor, improve efficiency and other core competitive advantages, and effectively reduce costs, many companies are pouring research and development efforts, constantly innovate, to create a series of high-performance motor products.

At present, traditional silicon steel sheet materials still occupy a dominant position in the market, but with the continuous innovation of material science and core application technology, some high-end soft magnetic materials, such as extremely thin/ultra-thin silicon steel, less/no heavy rare earth permanent magnets, 6.5%Si high-silicon steel, soft magnetic composite materials and amorphous/nanocrystalline alloys, have gradually received attention from the industry. At the same time, although centralized drive technology is still the mainstream choice, distributed drive technology, especially wheel edge motor and hub motor, has become an important direction of new energy vehicle technology research and development because of its short transmission path and advantages such as independent control of the torque between axes or wheels.

The key materials that affect the performance and cost of the drive motor include permanent magnets, silicon steel sheets, copper wires, etc. In the future, it is necessary to focus on the development of high-strength, low-loss silicon steel and new soft magnetic materials, low-weight rare earth/non-heavy rare earth permanent magnets with high temperature resistance, high-conductivity, low-loss super copper wires, and insulation systems with corona resistance and high thermal conductivity.

The new soft magnetic materials include 6.5%Si high-silicon steel, amorphous/nanocrystalline alloy, soft magnetic composite materials, etc. 6.5%Si high silicon steel manufacturing process is complex, resulting in difficult quality control, low production efficiency, high cost; Amorphous/nanocrystalline alloy has low saturation magnetic density, thin, brittle, hard material, difficult processing, and is more suitable for ultra-high speed and high electrical frequency motors. Ndfeb material is still the most important rare earth permanent magnet material, the use of Nd-Fe-B rapid quenching thermal deformation technology permanent magnet MQ3 material is one of the focus of new permanent magnet material. Reducing the amount of heavy rare earth is the current focus of research and development, grain refinement technology, intergranular technology, intergranular diffusion technology, comprehensive technology is the focus of research. In addition, electrically excited motors do not require the use of permanent magnets, and are also one of the industry's concerns and potential product choices.

Distributed drive is an important choice for the future development process of electrification, and it empowers each other with automatic driving. Distributed drive includes key technologies such as torque distribution and control, drive anti-slip control, fault-tolerant control and functional safety. At the same time, because distributed drive still has certain challenges in terms of handling and cost, it may be the first to be applied in high-end passenger cars and special vehicles (with high performance requirements and cost sensitivity). Wheel edge motor and wheel hub motor are two important technical routes of distributed drive. The wheel-edge motor can give full play to the electromechanical thermomagnetic multi-field design advantages of deeply integrated electric drive assembly, and realize the small and lightweight drive motor and reducer assembly system. Compared with wheel hub motor, wheel edge motor engineering design is less difficult, but there are still cost challenges.

Wheel motor faces multi-dimensional technical problems such as heat dissipation, sealing, control and impact resistance, and still has a long way to go in large-scale production applications in the field of passenger cars. It needs to make key breakthroughs in engineering design and verification such as efficient thermal conductivity and cooling heat dissipation technology, dustproof and waterproof, low resistance sealing technology, and integrated Angle module technology.

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