Boosting Electric Motor Performance & Longevity
Partial discharge poses a major challenge for developing long-lasting, high-performance electric motors, especially for use in electric air-mobility. The effect of partial discharge between the individual conductors will damage the insulation, and significantly reduce the life of the electric motor.
Daikin Chemicals joint development partner Additive Drives addresses this challenge in the development of new electric motors. The Partial Discharge Inception Voltage (PDIV) level can be increased by adjusting the wiring. Simulation tools are used to improve and verify the winding design, ensuring it effectively mitigates partial discharge. Furthermore, they utilize Daikin’s PFA insulated magnet wire for optimal performance. Comparative testing has consistently shown superior PDIV levels compared to traditional insulation materials.
By halving the insulation thickness by 50% compared to PAI enameled wire, they achieved a significantly higher copper fill factor within the motor slot, leading to a continuous power increase exceeding 10%. Motor efficiency also saw substantial gains.
This advancement has broad applications, unlocking new possibilities for high-performance, efficient electric motors:
- 800+ V for passenger cars, commercial vehicles and heavy trucks
- Durable rail and traction drives
- Powerful aviation e-drives
Additive Drives and Daikin Chemicals have invested in in-house production of wires which enables particularly fast prototyping and rapid validation of the concepts. The use of standard manufacturing equipment ensures that the production process is scalable for future needs.