Abstract
For the shift towards electric cars and to reduce CO2 emissions and global warming, superior electric cars with improved motor efficiencies are needed. This can be enabled by new designs for critical components, such as electrical windings in motors. It may not be possible by using conventional techniques and new methods such as additive manufacturing (AM) are required. Accordingly, an interdisciplinary team will explore the possibilities of producing AM electric motor windings for electric vehicles from copper using electron beam melting (EBM) and Laser Powder Bed Fusion (LPBF). In this project consortium, coordinated by Sweden Research Institute RISE (SE), the copper powder will be bought from Sandvik, KTH (SE), and Wayland will take the lead to improve the possibilities of additive manufacturing EBM/LPBF of copper electrical windings. Afterwards, instructions and guidelines will be conveyed to the end-users Xylem (SE). Using these, Xylem will design, optimise and revise new AM windings. Scania will be involved with validation of these solutions. These will be manufactured by KTH and Wayland. Afterwards, the windings will be insulated using different techniques, RISE (SE). The insulated test samples and windings will be tested by Scania (SE) to ensure insulation quality and applicability. After approving the insulations, Scania, and Xylem will assemble/test/analyse the performance. Clever Compliance (SE) will help streamline product compliance processes and ensure sustainability is kept in focus throughout the value chain.  
Consortium

COORDINATOR

  Clever Compliance

Stacy Trey

PARTNERS

Clever Compliance

Scania

Xylem

Royal Institute of Technology, KTH (Kungliga Tekniska Högskolan)

RISE Research Institutes of Sweden AB

The University of Sheffield, Advanced manufacturing research center

Wayland

Fintek