Introduction: A Game-Changing Solution for Electric Vehicles
The electric vehicle (EV) market is undergoing a profound transformation, driven by the global push for sustainability, advancements in clean energy technologies, and the urgent need to reduce carbon emissions. This shift is creating both opportunities and challenges for the automotive industry and its supply chain.
To thrive in this competitive and rapidly evolving landscape, companies must not only innovate but also ensure scalability and efficiency in production. At the heart of this revolution lies the ability to design and deliver cutting-edge components, such as next-generation electric motors, that meet the demand.
At IMA EV-TECH, in partnership with MAVEL, we are focusing on the development of advanced motor technologies specifically designed for EV applications. By combining our extensive experience in developing and manufacturing assembly machines with MAVEL's advanced knowledge of high-speed, high-power, high torque density motors, we deliver real value to our partners. This value is anchored in two fundamental principles: the creation of versatile, high-performance technologies that adapt to market needs and the deep process knowledge that enables collaborative innovation and continuous optimization.
Our CFW motor technology represents a perfect match of this approach, offering not only unparalleled performance but also a scalable and efficient production process. With its advanced design and manufacturing capabilities, it is poised to drive the next wave of innovation in e-mobility, setting new benchmarks for the industry.
IMA EV-TECH: Advanced Process Technology
IMA EV-TECH’s expertise is focused on providing the advanced machinery necessary for producing the Continuous Formed Winding motor (CFW). This next-generation motor, produced by MAVEL, relies on a meticulously engineered manufacturing process to ensure its efficiency, reliability, and scalability.
The automated solutions developed by IMA EV-TECH are tailored to meet the specific needs of CFW production. Unlike traditional methods, which often involve pressing and deformation risks, the CFW process uses non-linear slot paths with nearly circular designs. This innovation ensures that wires are inserted without causing deformation, ensuring high reliability and reduced scrap rates
Additionally, continuous winding patterns eliminate the need for excessive soldering, simplifying production and enhancing durability. The entire process is fully automated, with advanced machinery overseeing critical tasks, from wire preparation to final assembly. By reducing manual intervention, IMA EV-TECH ensures consistent quality and high output, even in large-scale production environments.
Efficiency and Scalability in Manufacturing
IMA EV-TECH’s machines are designed to optimize production efficiency while maintaining flexibility for future scalability. The manufacturing line for CFW motors has a compact footprint of 18 x 35 meters and operates at an impressive cycle time of just 83 seconds per stator. With an annual capacity of 193,000 units and an overall equipment effectiveness (OEE) of 85%, it sets new benchmarks for productivity in EV motor manufacturing. Key advantages of this process include a 10% reduction in operational and capital investment due to lower energy consumption, efficient use of floor space, fewer machines required and a simplified maintenance demand. The high degree of automation reduces the need for manual labour, streamlining operations and enabling manufacturers to quickly adapt to evolving market demands.
MAVEL: Next-Generation Motor Production
This motor features advanced technologies designed to optimize efficiency and performance. The AC losses mitigation slot enclosure consistently reduces losses at high speeds while maximizing the copper fill factor, resulting in enhanced overall efficiency. The design is compatible with all rotor topologies, enabling the reduction of airgap harmonics, minimizing rotor losses, and improving magnet utilization for superior performance.
The motor incorporates a direct slot oil cooling system, engineered for effective heat extraction. Robust sealing ensures reliable stator-to-rotor fluid separation, maintaining optimal thermal management. Additionally, the production-ready design includes a slot curvature that allows for compact end windings, preventing plastic deformation during insertion. The continuous winding pattern further minimizes welding points, streamlining the production process and increasing manufacturing efficiency.
Motor Performances
In terms of power and density performance, the motor excels with a peak current density of 65 A/mm² and a continuous current density of 40 A/mm². It offers a power density of 17 kW/kg, delivering 160 kW in just 9.5 kg. The torque density is also remarkable, providing 16 Nm/kg and achieving 150 Nm in 9.5 kg. Furthermore, the motor features a copper density of 100 kW/kg, resulting in 160 kW in just 1.6 kg of copper. The magnet density is equally impressive, with 230 kW/kg, delivering 160 kW in only 0.7 kg of magnet material. This combination of density and efficiency ensures exceptional performance in a compact, high-powered design. Conclusion: A Partnership for the Future of E-Mobility The collaboration between IMA EV-TECH and MAVEL is setting new standards for the EV market by delivering not just advanced motors, but also the machines to produce them efficiently at scale. By focusing on the machinery and processes that enable motor production, IMA EV-TECH empowers MAVEL to meet the demands of a rapidly evolving industry. This approach ensures that manufacturers have access to reliable, scalable, and cost-effective solutions that drive innovation in e-mobility.
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