China3D printingNet, March 5th, the Future Motor Manufacturing (FEMM) Center announced a new sustainable development project to ensure that increased electrification will not cause British landfills to be overwhelmed by excess parts.
The project funded by the Engineering and Physical Sciences Research Council (EPSRC) focuses on achieving a more circular economy and will enable three British universities to develop more sustainable life cycles for electric motors.This will include an initial assessment of the current supply chain and the determination of more suitable manufacturing methods (including3D printing) To eventually recycle the material back to the manufacturing facility.
Partners in the project include the Advanced Forming Research Center (AFRC) of the University of Strathclyde, the University of Sheffield and the University of Newcastle.
Dr. Jill Miscandlon, AFRC’s senior manufacturing engineer, explained: “It is important that electrification efforts do not further negatively affect ourselves on the production line. We don’t want ourselves to transition to electric vehicles, airplanes, and wind turbines, which are electric vehicles. , Aircraft and wind turbines will be landfilled at the end of their useful lives.”
Dr. Jill Miscandlon, AFRC Senior Manufacturing Engineer. Filmed via FEMM Hub.
Electrification: a double-edged sword
Most electrical systems today (such as EV motors) are produced using conventional manufacturing processes and limited virgin alloys. The disposal of these systems was rarely considered extensively in the initial design phase, so many of them ended up in landfills. In the next few years, with the inevitable growth of motor output, these limited raw material alloys will be consumed exponentially, putting pressure on industries such as automobiles, aerospace, and renewable energy.
When talking about the need to recycle raw materials, Miscandlon added: “We need to strike a balance between designing motors with outstanding performance, while ensuring that these materials can also be recycled for further use. We must definitely move towards clean energy solutions and electrification. But it is crucial that we consider the long-term impact of these decisions as early as possible.”
Redesigned for3D printingElectrical system
In addition to the end-of-life projects in the development of the UK supply chain, the project partners will also completely redesign certain electrical systems, some of which will be redesigned for3D printing. This includes a set of coils for EV motors and eVTOL vehicles.
The performance of the motor is mainly limited by its ability to dissipate energy loss, which we call “unnecessary heat”. For now, due to poor heat dissipation, the electrical windings in most modern motors are the main performance bottleneck, throttling energy efficiency, power density and torque density. Therefore, the improvement of the coil cooling system can help elevate electric vehicles to a new level of application.
The project team will work with two unnamed industrial partners to redesign and3D printingCopper coils with integrated cooling channels to prove the applicability of metal additive manufacturing in this application. Coils produced using powder bed fusion technology will be compatible with liquid-cooled star points to improve heat dissipation. The feasibility of cooling channels will be evaluated in order to promote dialogue between motor designers and manufacturers.
Miscandlon concluded: “With the FEMM hub, we are redesigning the motors to ensure they can achieve the best performance and address key challenges in the process, so that we are in the first place to consider remanufacturing from the beginning.”
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The concept of copper coil” alt=”A set installed on the stator part
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A set installed on the stator part3D printingThe concept of copper coils. Picture from FEMM Hub.
China3D printingInternet comment: As sustainability has gradually become the focus of attention, about3D printingThe discussion of circular economy in the industry is developing day by day.Researchers from the German Federal Institute for Materials Research and Testing have recently developed a new type of sustainability that uses termite waste.3D printingMaterial.Combining powdered wood and feces left by insects, the team was able to formulate reusable materials for adhesive spraying3D printing.
Elsewhere, car manufacturer Renault recently announced the establishment of a “Re-Factory”, a factory dedicated to sustainable car production.The manufacturing plant is located near Paris and will work to reduce waste by recycling and remodeling vehicles and provide3D printingSpare parts service.
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