UK-Alumotor-2 for LCV

里卡多花了十年的时间开发无磁铁，可持续的，同步磁阻，牵引电机技术，它保留了富磁电机的属性。作为其中的一部分，里卡多正在完成DER“UK-Alumotor 1”供应链开发项目，该项目为铝制绕组、低损耗定子制造和带有增材制造磁导的转子复合材料提供了制造学习。这是与我们的合作伙伴：Aspire；Brandauer;GTR;常设调查小组委员会;WMG和DER卓越卷绕中心。本项目采用以上的学习和概念，显著提高轻型商用车（LCV）概念电机的制造准备水平（MRL）。我们将提供一个“制造设计”（DFM）项目，一个预生产的、高度可持续的电机，每台机器去除12kg的稀土磁铁。我们将开发供应链中的制造流程，电机的数字孪生，包括制造影响，从摇篮到坟墓的生命周期分析（LCA），以及目标定价与数量数据输出的商业案例。第一个项目阶段将开发DFM解决方案，采购、组装和测试第一次迭代电机，这将用于验证数字孪生仿真模型。第一个迭代电机定子将由DER资助的WMG绕组卓越中心与Aspire联合使用Brandauer提供的层压堆栈制造。第二，虚拟DFM阶段将通过LCA、性能和耐久性测试结果的反馈来优化制造过程。这种优化将通过数字孪生工具链进行评估，包括虚拟验证。另一项并行任务将推进DFM和更高性能转子的制造过程，其中包括来自英国alumotor 1项目的新型复合材料。这将扩大电机对更高性能的国防和乘用车应用的吸引力。进入市场的路线将通过对潜在客户和市场的商业研究，以及对每年5,000或100,000个单位所需的装配厂的审查来确定。这将为里卡多和合作伙伴的小批量和大批量生产的投资决策提供信息。更多的商业化将来自里卡多和合作伙伴在客户电机设计和开发项目中的学习。这将提高合作伙伴在英国的竞争力，并从Innovate UK DER资金中获得更多价值。

Ricardo has spent ten years developing magnet free, sustainable, synchronous-reluctance, traction motor technology, which retains the attributes of magnet-rich motors. As part of this, Ricardo is completing the DER "UK-Alumotor 1" supply chain development project, which has delivered manufacturing learning for aluminium windings, low wastage stator manufacture, and composites in rotors with additive manufactured flux guides. This has been delivered in conjunction with our partners: Aspire; Brandauer; GTR; PSI; WMG and the DER Winding Centre of Excellence.This project takes the learning and concepts from the above to significantly increase a light commercial vehicle (LCV) concept motor's Manufacturing Readiness Level (MRL). We will deliver a "design for manufacturing" (DFM) project of a pre-production, highly sustainable motor removing 12kg of rare-earth magnets per machine. We will develop the manufacturing processes in the supply chain, a digital-twin of the motor including manufacturing influences, a cradle to grave Life Cycle Analysis (LCA), and a business case with target pricing versus volume data output.The first project phase will develop DFM solutions, procure, assemble and then test first iteration motors, which will be used to validate the digital-twin simulation model. The first iteration motor stator will be manufactured by the DER funded Winding Centre of Excellence at WMG jointly with Aspire using lamination stacks provided by Brandauer. A second, virtual DFM phase will optimise the manufacturing processes through feedback from the LCA, performance and durability test results. This optimisation will be assessed via the digital-twin toolchain, including virtual validation.A parallel task will progress the DFM and manufacturing processes for a higher performance rotor that includes novel composites from the UK-Alumotor 1 project. This will widen the attractiveness of the motor to higher performance Defence and passenger car applications.The route to market will be identified by a business study of potential customers and markets, and a review of the assembly plants required for 5,000 or 100,000 units/year. This will inform investment decisions for Ricardo and partners for low and high-volume manufacturing.Additional commercialisation will come from deploying the learning by Ricardo and partners in client motor design and development projects. This will increase the partners' competitiveness in the UK and deliver further value from the Innovate UK DER funding.