UK-Alumotor-2 for LCV

里卡多花了十年时间开发无磁、可持续、同步磁阻牵引电机技术，该技术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-RESISTANT motor 1”供应链开发项目，该项目已提供铝绕组、低损耗定子制造和转子复合材料的制造学习，并采用增材制造的磁通导向器。这是与我们的合作伙伴Aspire、Brandauer、GTR、PSI、WMG和DER绕线卓越中心共同完成的。该项目利用上述学习和概念，显著提高了轻型商用车（LCV）概念电机的制造就绪水平（MRL）。我们将交付一个“面向制造的设计”（DFM）项目，该项目是一个预生产的、高度可持续的电机，每台电机可去除12公斤稀土磁体。我们将开发供应链中的制造流程，包括制造影响的电机数字孪生模型，从摇篮到坟墓的生命周期分析（LCA），以及目标定价与批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，组装然后测试第一个迭代电机，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卓越绕组中心与Aspire共同使用Brandauer提供的层压堆栈制造。第二个虚拟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流程。这种优化将通过数字孪生工具链进行评估，包括虚拟验证。一项并行任务将推进DFM和制造工艺，以获得更高性能的转子，其中包括来自英国-英国发动机1项目的新型复合材料。这将扩大该电机在更高性能的国防和乘用车应用中的吸引力。将通过对潜在客户和市场的业务研究以及对5，000或100，000台/年所需装配工厂的审查来确定市场路线。这将为里卡多及其合作伙伴的小批量和大批量生产提供投资决策信息。额外的商业化将来自于将里卡多及其合作伙伴的学习部署在客户电机设计和开发项目中。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.