'Proto-LAMINATE' for Proto-Lamination and Magnetic INTegrated Assessment Test Exercise

随着汽车行业寻求拥抱电气化，这是实现净零排放目标和未来英国绿色经济的一部分，为零排放汽车及其组成部分和系统的设计、制造和回收提供了发展可持续和具有竞争力的英国供应链的机会。通过汽车转型基金(ATF)等创新资助服务，英国政府寻求通过加快业务创新和增加研发投资来支持这些发展。通过电气化实现零排放汽车的愿景需要在英国汽车PEMD供应链上开发新的面向制造的设计流程和产品。ATF的这项提案旨在调查这一转型的一个重要方面，目前这是英国供应链中的一个缺口：低成本原型和小批量生产电动马达叠层的新工艺的可行性。在开发新的电动马达产品时，关键的一步是使用小批量原型组件测试和验证设计。这些组件必须在配合、形式、功能，特别是与性能相关的性能方面代表最终产品，准确地表示通过最终生产过程实现的那些性能。尤其是在汽车应用中，最终产品很可能是安全关键车辆系统的一部分。另一方面，汽车应用对成本高度敏感：因此，有必要最大限度地减少开发成本，同时仍能达到所需的开发严格性水平。该项目寻求开发和测试--与真正的汽车电动马达开发计划--相结合的新工艺，以实现快速、高质量、低成本地制造电动马达叠层样件的原型(或小批量生产)。拟议的新制造流程的提供将促进英国PEMD供应链，并有助于未来的可持续性--例如，通过消除堆叠组件中的环境有害粘合剂和减少制造浪费。拟议的合作伙伴包括汽车系统的一级供应商ZF Automotive，英国的产品设计、原型制作、组装和测试服务提供商H V Wooding，涉及一系列工程领域的产品设计、原型、组装和测试服务提供商，以及考文垂大学制造和材料工程中心的计量小组。这一合作伙伴关系将制造工艺能力、工艺和产品公差分析的计量专业知识以及最终用户组装和综合测试专业知识结合在一起，使新工艺得以定义并充分体现为更广泛的汽车电动马达开发计划的一部分。

As the automotive industry seeks to embrace electrification, part of the drive toward net-zero emissions targets and a future UK green economy, opportunities arise for development of sustainable and competitive UK supply chains for design, manufacture and recycling of zero-emission vehicles and their constituent components and systems. Through its innovation funding services such as the Automotive Transformation Fund (ATF), the UK government seeks to support these developments through accelerating business innovation and boosting R&D investment.Realising the vision of zero-emission vehicles through electrification requires development of new Design-for-Manufacture processes and products across the UK automotive PEMD supply chain. This ATF proposal seeks to investigate an important aspect of this transformation, which currently is a gap in the UK supply chain: the feasibility of new processes for low-cost prototyping and small series production of e-motor lamination stacks.In developing new e-motor products, a critical step is testing and validating designs using small batches of prototype assemblies. These assemblies must be representative of the final product in terms of fit, form, function, and particularly performance-relevant properties, accurately representing those achieved through final production processes. This is especially the case in automotive applications where the final product may well be part of a safety-critical vehicle system. On the other hand, automotive applications are highly cost-sensitive: hence, there is a need to minimize development costs whilst still achieving the required level of developmental rigour.This project seeks to develop and test -- in conjunction with a real automotive e-motor development programme -- new processes that enable rapid, high-quality, low-cost manufacturing of prototype (or small volume production) samples of e-motor lamination stacks. The provision of the proposed new manufacturing processes will boost the UK PEMD supply chain and contribute to future sustainability -- for example by eliminating environmentally-harmful adhesives from stack assemblies and reducing manufacturing waste.The proposed partnership includes ZF Automotive, a Tier-1 supplier of automotive systems, H V Wooding, a UK provider of product design, prototyping, assembly and testing services across a range of engineering areas, including lamination stacks for e-motor assemblies, and the Metrology group of the Centre for Manufacturing and Materials Engineering at Coventry University. The partnership brings together the manufacturing process capabilities, the metrology expertise for process and product tolerance analysis, and the end-user assembly and comprehensive testing expertise required to enable the new processes to be defined and fully characterised as part of a wider automotive e-motor development programme.