The following era of electrical drives provides improved effectivity, energy density, efficiency, and sustainability.
In its subsequent e-drive era, Magna has additional improved the e-motor, energy electronics, and cooling system and decreased the necessity for Heavy Uncommon Earth (HRE) supplies. Furthermore, the next-generation provides enhanced system efficiency by way of the software-based, Optimized Pulse Patterns (OPP). The enhancements profit effectivity and efficiency, in addition to sustainability.
The brand new 248 kW electrical motor, developed inside the LG Magna collaboration, achieves its excessive efficiency regardless of considerably decreased heavy uncommon earth supplies. The rotor accommodates no terbium and a minimal per mile of dysprosium. The ability density is 8 kWp/kg, the utmost velocity is 20,000 rpm, and the height effectivity reaches greater than is 96%, with a extensively elevated candy spot. The e- drive system effectivity is 93%.
Sustainable manufacturing and recycling strategies additional scale back the ecological footprint. For instance, the magnets are inserted mechanically within the rotor and glued by flaps, without having for over-moulding. The drive system incorporates a compact bundle that may be tilted to 90 levels across the drive axis on account of its comparable x and z dimensions. This flexibility additionally advantages AWD platforms with totally different entrance and rear axle packaging necessities.
A newly developed Lively Fluid Management (AFC) controls the coolant circulation for various working factors of the e-motor, i.e. excessive motor speeds result in increased rotor losses. AFC permits for various and reversing the oil circulation inside the e-motor system. One working state is directing the oil to the winding heads for cooling. When reversing the pump motor operation, part of the oil circulation is moreover directed into the rotor shaft. The improved cooling considerably improves the system effectivity and permits for utilizing extra sustainable magnets.
HV Embedding is one other component that improves system effectivity. Often, the switching modules can be separate SiC chips plugged into the inverter’s PCB (printed circuit board). With HV Embedding, the SiC chip is embedded right into a copper cell, which is then built-in into the HVE PCB. As a consequence of much less ohmic and inductive resistance, the system reduces switching losses and permits for a extra steady management circuit.
One other main innovation is OPP. This software-based idea permits for higher effectivity of the general electrical drive and interaction of its parts. The principle premise for working a three-phase electrical drive is to generate appropriate pulse patterns. These patterns consequence from changing a quasi-digital sign from the inverter to a sine waveform within the e-motor. The ‘high quality’ of the waveform defines the ability output and effectivity and ought to be optimized for each load level. Magna optimizes the patterns accordingly on the take a look at bench after which consists of the ‘pulse patterns’ within the inverter software program. Usually, this permits increased energy availability and effectivity particularly at excessive velocity, and reduces the price of the magnets. On the system degree, using OPP can scale back losses by as much as 30%, relying on the working level.
The brand new electrical drive system will launch in 2027. Magna can also be engaged on additional developments, together with digital twin integration, energy electronics developments, and electrical motors with out uncommon earth supplies. These ongoing improvements purpose to enhance sustainability, effectivity, prices, and energy density, progressively incorporating them into Magna’s modular product system.
