The Book of Innovation by Advanced Electric Machines (AEM)

ADVANCED ELECTRIC MACHINES

THE BOOK OF INNOVATION

LET’S INNOVATE Welcome to The Book of Innovation from Advanced Electric Machines (AEM). The purpose of this book is to share a valuable and important story. It’s the story of facing down one of the biggest challenges in technology and manufacturing – the drive towards electrification – and how a company and its partners are rising to meet this challenge. AEM has been at the forefront of the shift to electrification in the UK since our founding in 2017, working to develop electric motors and powertrain technology in applications from passenger cars and commercial vehicles through to agriculture and aerospace equipment.

In the pages that follow, the goal is to highlight not only the importance of electrification in tackling climate change but also to showcase the projects and technologies that have emerged from the incredible talent, innovative thinking and deep collaboration of which AEM has been a part over the last five years.

CONTENTS A global success story

The challenge of electrification 12 AEM’s technology

Sectors and applications

Projects

This book celebrates a British success story and how organisations, academic and research partners working together can build a better and brighter future.

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A GLOBAL S U C CE S S S T ORY. MADE IN BRITAIN. Advanced Electric Machines (AEM) deliver the most sustainable electric powertrain technologies in the world with market-leading performance. Electrification is key to tackling the climate crisis, but only if the technologies developed are more sustainable to manufacture, use and recycle than those they replace. Most people immediately think electric vehicles are green. Sadly, that is not always true, as they often use materials and designs that are less than sustainable.

Current electric motors rely heavily on rare earth magnets and copper, which are not only damaging to the environment in their extraction and production but are also subject to price volatility and supply issues. With over 128 million electric vehicles to be sold annually by 2041, this could create a huge problem unless we find another way.

AN OPPORTUNITY The pioneering work of Newcastle University’s School of Engineering into advanced electric drives developed a new technology that helped Jaguar Land Rover build its first electric vehicle and Airbus complete the world’s longest flight using an electric motor. Leading that research was Dr James Widmer, who saw an opportunity for a company to develop and manufacture an alternative to traditional and unsustainable electric motors. Advanced Electric Machines was founded in March 2017 by James and

Dr Andy Steven and has since secured over £25 million of investment to continue developing and expanding these technologies with a range of partners and customers. Over the past five years, Advanced Electric Machines (AEM) has been working with world-class academics, global vehicle manufacturers and leading industrial partners. It aims to deliver the most sustainable and highest performing solutions for electric vehicles, from passenger cars and trucks to tractors and aerospace.

AEM DELIVER THE MOST SUSTAINABLE ELECTRIC POWERTRAIN TECHNOLOGIES IN THE WORLD WITH MARKET LEADING PERFORMANCE

THE FUTURE AEM has already manufactured a range of electric motors for these sectors that align with the goal of helping customers go faster and further whilst remaining greener than other technologies by eliminating environmentally harmful primary rare earth materials. AEM also removes copper, which means its electric motors are fully recyclable at end-of-life. As a result, the electric motors developed by AEM are the most sustainable in the world while delivering efficiency and market-leading power densities.

OUR MISSION AEM will design and build the most sustainable electric motors on the planet, supplying them around the globe from our facilities in the UK. AEM aims to make greener power more accessible to every part of the world.

OUR VISION Electrification is key to addressing climate change only if the technologies developed are more sustainable to manufacture, use and recycle than those they replace. AEM utilises its partnerships and expertise in materials, manufacturing and design to ensure every product delivers a more cost-effective, higherperforming and greener solution for all our target sectors.

AEM AIMS TO MAKE GREENER POWER ACCESSIBLE TO EVERY PART OF THE WORLD

THE CHALLENGE OF ELECTRIFICATION Electric vehicle use is growing in every area of transportation from passenger cars to buses, marine and aerospace. But while electric vehicles offer a route to zero emissions, their manufacture leaves a lot to be desired. Here’s the challenge facing electrification now and in the future. The case for electrification is clear. Electrification is critical to meet the UK’s net-zero target by 2030 and move the motor industry towards a more sustainable future.

in electric vehicles required to slash emissions over the next decade.

However, while electric vehicles offer transport with zero emissions, the supply chain is far from as sustainable and environmentally sound as it needs to be, given the vast increase

Right now, the current generation of electric vehicles – and electric vehicles coming onto the market in the next few years - are still a long way from being truly sustainable. The best electric drivetrains in the industry rely on rare earth magnets and copper as core materials.

RARE EARTH MAGNETS The impact of extracting rare earth magnets is high. As the electric vehicle market grows rapidly, so does the demand for rare earth materials. Until the electric car market can find a way of removing and recycling as much rare earth magnets as possible, the shift

to electrification will cause challenges further down the supply chain. The process of extracting and processing rare earth magnets results in a huge amount of pollution and waste.

FOR EVERY 1 TONNE OF RARE EARTH PRODUCED...

6 0 , 0 0 0 M3

of waste gas that contains hydrochloric acid

2 0 0 M3

of acid-containing sewage water

1 -1 . 4 T O N N E S of radioactive waste

2 7. 6 T O N N E S

of CO2 equivalent released to the atmosphere 12

COPPER

According to The Financial Times, if electric vehicle sales penetration hits 40 per cent by 2030, around eight times more lithium, nickel and copper will be required for annual electric production.

90 Copper Used in Cars (kg)

Copper is a significant material in electric vehicles, with an average of 83kg of copper used. This is a much higher level of usage than other types of cars. Copper is a difficult material to recycle. There are many harmful effects from mining copper, including contamination of local ecosystems, acid leaching, damage to water suppliers and waste.

80 70

83kg

60 50

60kg

40 30 20 10 0

39kg 8-22kg

Petrol & Diesel

Hybrid

Plug-In Hybrid

Electric

Overcoming the challenges with electrification requires solutions that focus on reducing the usage and need for rare earths and copper while maintaining reliability and performance.

FASTER, FURTHER, GREENER Advanced Electric Machines (AEM) is stepping up to the challenge of bringing sustainable solutions to market that improve upon range, speed, sustainability and, importantly, cost. Here is how it aims to go faster, go further, be greener and at lower cost than the alternatives.

AEM’S MOTORS RUN FASTER AEM produces higher speed motors that are lighter and more power-dense without using unsustainable materials or requiring complex electronics. AEM’s SSRD traction motor is designed to operate at 30,000 revolutions per minute, significantly faster than any motor currently in volume automotive production. This rotational speed was initially selected as it was shown to form the basis for the most cost-effective possible EV powertrain. However,

High rotational speed

Uniquely wide speed range

• S SRD runs up to 30,000 rpm

• Full vehicle speed ranges

• A llows for a smaller, lighter design • P rovides for a simpler, less expensive motor Segmental rotor design • More compact rotor • M aximises torque and efficiency • A llows for very high speeds

experience has now shown that it can also enable the world’s highest performance electric cars. Work with partner Bentley has demonstrated that SSRD will allow a highperformance electric vehicle to operate up to the highest speeds without a need for a complex transmission. Removing the transmission makes the vehicle lighter and increases acceleration. The figure shows a comparison between the rotational speed of AEM’s SSRD motor and rivals.

Patented gear design • S implified, singlespeed transmission • M inimised transmission losses

AEM’S MOTORS TAKE YOU FURTHER AEM’s motors offer the potential for up to 15% increase in vehicle range operate with lower complexity and therefore lower cost transmission. A major commercial vehicle customer has reported that they expect AEM’s HDSRM commercial vehicle traction motor to increase their vehicle range by 10%. Another major passenger vehicle manufacturer has said that AEM’s SSRD traction motor will extend its cars’ range by 15%.

Based on AEM’s modelling and testing to date, this increase in range can be attributed to several key technology factors: • AEM’s fundamental motor technology has inherent efficiency advantages through their physics, this is coupled with a design approach that optimises the motors to meet specific customer’s needs • AEM’s compressed aluminium windings reduce

high-speed losses in the motor, allowing the motor to operate efficiently across the full speed range • AEM’s ‘efficiency boost’ technology, used in dual-motor systems, allows a single motor to be switched off when it is efficient to do so; this significantly increases the peak efficiency region of powertrain operation.

AEM’S MOTORS ARE AT PEAK EFFICIENCY ACROSS M O R E O F T H E R E A L- W O R L D O P E R A T I N G P O I N T S . THE MOTORS DELIVER A 12% REDUCTION IN THE ENERGY USED, MEANING A REDUCTION IN THE SIZE OF THE BATTERY REQUIRED TO OFFER THE SAME RANGE.

133M TONNES OF CO2 EQUIVALENTS SAVED PER YEAR

AEM’S MOTORS ARE GREENER AEM’s motors save on emissions, CO2 and waste. Cutting down on emissions isn’t the only environmental advantage AEM motors bring. AEM’s motors also save…

• 133 m tonnes of CO 2 equivalents saved per year compared to other motor electrification solutions available on the market today (the same as removing 29m additional petrol cars from the road each year). • 300k tonnes of radioactive waste saved by eliminating the use of polluting rare earth magnets in our traction motors. • 5m tonnes less landfill produced per year as no rare earths metals or copper enable our motors to be fully recyclable at end of life.

AEM’S TECHNOLOGY IS LOWER COST AEM’s motors eliminate the need for the two most expensive materials used in motor manufacturing – rare earth magnets and copper. As well as achieving the sustainability benefits of removing these materials, the lower manufacturing cost is also a significant benefit. Further, the use of AEM’s compressed aluminium conductors reduces motor conductor costs by circa 90%.

AEM’s motors are designed to reduce the overall cost of the electric powertrain. The SSRD motor was initially developed as part of a programme called “Low Cost Electric Drivetrain”, designed to reduce not just the cost of the motor but the system overall. Additional savings are made by ensuring that cost-effective power electronics can drive the motor. SSRD uses at least as cost-effective power electronics as the industry

standard and an interior permanent magnet motor reduces the size of the battery needed to drive the vehicle. These factors enable SSRD to offer a lower expected manufacturing cost than any other motor technology on the market.

AEM VALUE PROPOSITION FASTER

FURTHER

LOWER COST Permanent Magnet (e.g. Lucid/ Tesla) Induction Motor (e.g. Tesla, Audi) SRM (e.g. Turntide)

Higher rotational speed means: • Smaller, lighter motor • Simpler, less expensive

Customers report that AEM motors improve vehicle real world range by up to 12%

AEM motors significantly reduce customer system costs

GREENER Permanent Magnet (e.g. Lucid/ Tesla) Induction Motor (e.g. Tesla, Audi) SRM (e.g. Turntide)

AEM motors are more sustainable than competitors

AEM’S TECHNOLOGY AEM offers market-disrupting, competitive solutions through its proprietary and differentiated technology portfolio

HDSRM Specifically designed for Commercial Vehicle applications, HDSRM offers a direct ‘plug and play’ replacement for permanent magnet machines, increasing range by up to 12% while driving significant efficiencies for customer fleets

Benefits:

Applications:

• Rare earth free and copper-free • Plug and play electric motor for a range of applications • Easily integrated across vehicle powertrains and platforms • Available in three performance specifications with more in development Compared to permanent magnet motors: • 45% improved power to weight ratio • 15% increase in range across WLTP drivecycle • Simpler and lower cost transmission • Fully recyclable without disassembly

Agricultural, commercial, off-highway

The facts:

PARAMETER

PERFORMANCE

Peak Torque

Up to 520Nm@450Arms (HDSRM300T)

Peak Power

Up to 214kW @700VDC (HDSRM300)

Ef ficiency

Up to 12% increase in range compared to PM based motors

Mass

75kg (HDSRM300/300T)

SSRD SSRD offers class-leading performance and sustainability for passenger cars by enabling a lower-cost electric powertrain system solution.

Benefits: • Rare earth magnet and copper-free • High performance integrated passenger car motor • Lightweight, robust design with high manufacturability and reliability • Single-speed, high reduction two-stage transmission

Compared to permanent magnet motors:

Applications:

45% improved power to weight ratio 15% increase in range across WLTP drivecycle Simpler and lower cost transmission

Passenger cars

Fully recyclable without disassembly

• Targeting production in 2024

HEAD World-record holding aerospace technology, representing the next generation of electric solutions for the aerospace markets and expanding AEM’s market opportunity. HEAD is designed for unmanned aerial drones (UAVs) and high altitude pseudo-satellites (HAPS), which will become essential to deliver wifi to remote parts of the world. Benefits:

Highlights:

• Powers solar aircraft with the ability to withstand extreme temperatures

• Extremely high efficiency, very low mass and reliable operation at -90C

• Built on compressed aluminium winding technology offering high efficiency with low mass

• Potential for automotive volumes at aerospace pricing • New market opportunity

Applications:

high altitude pseudo satellites, unmanned aerial vehicles

• Utilises recycled rare earth magnets for an improved environmental footprint

SECTORS AND APPLICATIONS PASSENGER CAR Offering the ultimate refinement of performance and sustainability, AEM’s passenger cars systems are market-leading.

OFF-HIGHWAY In the harshest of environments our motors offer routes to simplified systems and improved performance.

MARINE Flexible in design and performance, our motors can operate offshore.

THE TECHNOLOG DEVELOPING AN APPLICATION A

GY AEM AND ITS PROJECT PARTNERS IS ND MANUFACTURING HAS WIDE AND VARIED CROSS MULTIPLE SECTORS.

COMMERCIAL VEHICLES Robust, reliable and efficient, AEM’s motors have been specifically optimised for commercial vehicles.

AEROSPACE From propulsion to ancillary systems, AEM’s motors meet the demanding requirements of aerospace.

INDUSTRIAL From rolling mills to HVAC, AEM and its partners offer cost effective solutions.

INTRODUCING THE PROJECTS Having secured more than £25 million in investment, AEM and its partners are at the forefront of building a greener, more sustainable landscape for electric vehicles across all sectors. Here are the key projects AEM and its partners are working on. AEM brings together par tners from across the UK to collaborate on government-funded projects to fur ther develop this technology. Projects range from creating new, high-power, e -a xle systems with Bentley Motors for their worldrenowned luxur y cars to delivering a break through integrated solution for the nex t-generation of electrified agricultural vehicles with CNH Industrial. AEM is collaborating with some of the most for ward-thinking organisations

and educational institutions to build a bet ter, greener future. AEM also works alongside partners like HyProMag to extract, recycle and reuse previously-disposed rare earth magnets to power its world record-holding aerospace technology. This section of The Book Of Innovation explores each project, its scope and innovations and throws a spotlight on our partners and their contribution to each project.

OUR PROJECTS PROJECT OCTOPUS

PROJECT ELECTRA

PROJECT RARE

PROJECT CYGNUS

PROJECT SANGREAL

PROJECT OCTOPUS

HOW AEM IS DELIVERING A C OMPA C T, IN T EGR AT ED A ND C O S T-EF F E C T I V E E-A X L E WITH BENTLEY MOTORS

AEM is working in partnership with Bentley and other key partners to deliver the ultimate passenger car e-axle solution for use beyond the luxury car market. AEM has proved the efficiency and sustainability of its SSRD technology, yet there is one area of great importance to many original equipment manufacturers (OEMs) that doesn’t have as much support: performance. For a manufacturer like Bentley Motors, performance is everything. But with a commitment to transforming the luxury brand into the most sustainable, it’s vital to match sustainability with performance. AEM’s OCTOPUS project will deliver an e-axle, free of rare earth materials, that uses nextgeneration integrated power electronics to create marketing-leading power density and packaging characteristics in line with Bentley’s needs. This isn’t the first time AEM and Bentley Motors have partnered on a project of this nature. AEM previously worked with Bentley on APEX, its first Innovate-funded programme focused on proving the performance and the sustainability of its SSRD technology. The outcome from the APEX project was the development of additional innovations which will move to the patent stage in the future.

THE CHALLENGE Delivering the ultimate passenger car e-axle solution is a challenge that touches many issues: sustainability, rare earth issues, CO 2 emissions in production, CO 2 emissions in use and recyclability at the end of life. The key issues to address are four-fold • H ow do we extract rare earth materials sustainably? • H ow do we put together the materials? • H ow efficiently can we put together these materials? • W hen we’re finished with those materials, how do we make sure we dispose of them most sustainably?

OCTOPUS builds on this APEX project by applying leading-edge materials and manufacturing processes to push performance characteristics beyond APEX.

THE OPPORTUNITY The opportunity is to apply this cutting-edge approach to an iconic UK brand. However, the goal is not simply to narrow its application to best-in-class performance vehicles. This is a technology that can be applied to all cars. The simulation toolkit, test programmes and test rigs can be applied to the automotive and broader transport markets. These can be developed to become vital assets to other automotive organisations leading the development of electrification technologies. The wire production methodology and additive manufacturing process routes developed through the OCTOPUS project will also be suitable for use in the wider component manufacturing markets.

WHAT AEM IS DOING AEM aims to use everything available in the market in the best way to deliver a world-changing technology solution and push performance characteristics beyond those of APEX. The result is a solution that is more powerdense, more manufacturable and has a stronger performance characteristic. To achieve this, AEM is using Europe’s largest supercomputer network, one of the world’s largest microscopes and world-leading test and validation. It also bi together the latest carbonbased super materials — graphene and carbon monotube — with traditional materials thinking. The solution has reduced costs and footprint by applying leading-edge materials and manufacturing processes to remove rare earth materials and copper from the process. From this, it was important to develop a cutting-edge manufacturing process working alongside traditional manufacturing to deliver an integrated solution that reduces the system’s overall manufacturing and assembly costs. Among the critical design and simulation of motor, PE and integrated e-axle will be a range of manufacturing processes, including

wire production methodology for integrated aluminium and non-material wire additive manufacturing process routes. The output will be an integration plan for the Bentley platform and a complete business plan for the future manufacture and supply of the e-axle. The new manufacturing processes can be energy-intensive, and so the intention is only to use the technology when necessary. By utilising the installed asset base of the UK’s advanced manufacturing capability, manufacturers don’t have to spend millions on new tech and redesign processes and systems that already deliver low-cost economies. This also helps secure manufacturing jobs in the UK and encourages retraining of employees. There are also wider opportunities for partners to become involved in developing an end-to-end supply chain, providing an opening for using the technology in sectors beyond automotive. AEM has developed a truly sustainable solution to future transport that is world-leading in its performance, cost and recyclability.

AEM Proving performance capability of SSRD motor technology

PROJECT APEX COM

PLE

First Innovated-funded programme and opportunity for AEM to demonstrate the technology could deliver world-class performance.

BENTLEY MOTORS Looking to transform its range of vehicles over 10 to become more sustainable

JUL Y 202

SME TTPI

START OF PROJECT OCTOPUS Goal to deliver the ultimate passenger car e-axle solution for use beyond the luxury car market.

AEM

Responsible for design and optimisation of motor

DESIGN

BENLEY MOTORS

Development of vehicle package, e-axle requirements and design of e-powertrain

HIETA TTPI Leader of PE design and integration activity

INTEGRATED POWER ELECTRONICS SYSTEM

DIAMOND LIGHT SOURCE

MATERIALS & MANUFACTURING

UNIVERSITY OF BATH

TALGA Develop carbon nontube material to incorporate into aluminium conductors

OBSERVATION

Investigate stress-strain data produced by the motor at high speed

Support of transmission design, NVH and system level modelling

Design, build and test Additively Manufactured components

HARTREE CENTRE Production of ‘virtual electric motor’ simulation framework

TEST & SIMULATION

THE NEXT STEP?

UNIVERSITY OF NOTTINGHAM Production of ‘virtual electric motor’ simulation framework

BENTLEY MOTORS PROJECT OCTOPUS PARTNER PROFILE

Supporting Bentley’s goal to become the most sustainable luxury automotive brand in the world. Bentley Motors has been making sure its customers enjoy extraordinary journeys for over a century. Now, the luxury car manufacturer is taking the next step on its own development journey – one towards a particularly ambitious destination that sees Bentley becoming the most sustainable luxury automotive brand in the world. This route will see several significant milestones, including: • Having introduced two plug-in hybrid models in the past 12 months. This will be followed by the release of a plugin option for every model by 2024 • L aunching its first-ever electric vehicle in 2025, which will also be the world’s first luxury car to be carbon-neutral over its entire lifetime • Embracing electrification by 2026, producing only plug-in hybrid vehicles and battery electric vehicles • Committing to further reducing the environmental impact of its factory by 75% by 2025 – which includes going plastic-neutral • The company aims to be end-to-end carbon-neutral by 2030, becoming climatepositive with all of its operations at Crewe. From 2030 onwards, every car Bentley Motors creates will be a battery-electric vehicle.

THE BEYOND100 STRATEGY These commitments – which form part of Bentley’s “Beyond100” strategy – mean it will go from being the world’s largest producer of 12-cylinder engines to having no internal combustion engines in a single decade. This is a real transformation, but one that stays true to W. O. Bentley’s iconic vision: “to build a fast car, a good car, the best in its class.” To achieve these ambitious targets, the company needs to focus on every aspect of vehicle sustainability, including sustainable materials and methods of sourcing those components. This is why it is working closely with Advanced Electric Machines on leading research projects that will transform the automotive industry for the next 100 years. Bentley’s customers have always demanded cars that combine stunning design, exceptional craftsmanship and thrilling performance, and it will continue to deliver exactly these aims. But the luxury consumers of today and tomorrow are also looking for a brand-new form of sustainable and ethical luxury – and that is what “Beyond100” will create.

BENTLEY'S ROLE IN PROJECT OCTOPUS Bentley Motors' role within the OCTOPUS project is to define the technical targets for the powertrain to achieve. These targets include performance, weight, package, NVH and durability requirements, and other technical aspects, such as defining the vehicle's electrical, communication and mechanical interfaces. Of course, there are also commercial targets that need to be met. According to Bentley, this collaboration with AEM enables the manufacturer to demonstrate its commitment to electrification

and sustainability, collaborate with leading academic and commercial partners and identify opportunities to spit out further technologies. In the future, Bentley Motors sees its participation in the OCTOPUS project as being able to help build a deep understanding of alternative traction technologies, understand better the opportunities of additive manufacturing within powertrain applications and enhance Bentley's collaboration with other brands within the Volkswagen Group.

TTPI PROJECT OCTOPUS PARTNER PROFILE

“

A VALUABLE OPPORTUNIT Y TO GAIN INSIGHTS INTO AUTOMOTIVE TECHNOLOGIES. Being a part of the OCTOPUS project has been a valuable opportunity to gain insights into the challenging world of automotive technologies. Building links with the other partners and learning about their specialist fields presents exciting potential for future technical developments.” Dr Edward Christopher, Senior Engineer, TTPi

TTPi Ltd is a spinout from the Power Electronics Machine and Control group, a research group within the University of Nottingham. The company was formed with a vision to develop further, apply and commercialise IP and know-how relating to power electronics solutions created by the founders and their fellow researchers at the university. By 2023 TTPi will be a recognised contributor in transforming power electronics for sustainable transport and energy systems. TTPi’s standout features include its pushing technology and methods, providing solutions for wideband gap-based power conversion: • I ntegrated solutions from switchingcell to Converter-in Package • I ntegration options for gate drives, control, sensing, auxiliary supplies, filters and broadband EMI suppression • D eep integration with load/ source, e.g. integrated drives

As part of OCTOPUS, TTPi is responsible for providing innovative power electronics motor drives solutions. TTPi is using proprietary integration technologies, manufacturing techniques and control methodologies to deliver highly efficient high bandwidth and lowcost integrated power electronics specifically for integration within the motor frame. TTPi is providing innovative adaptive motor control algorithms to optimise drive characteristics such as efficiency, audible noise, torque generation over the entire speed/torque range. The ability to interact closely with the motor manufacturer is essential to derive an optimised solution, and the knowledge gained throughout this process has facilitated new and innovative product ideas. Being part of OCTOPUS enables TTPi to further understand the automotive sector’s needs and, as such, different ways of working and collaborating have been developed. New opportunities to collaborate are established and new products are being developed for both automotive and integrated drives applications. This supports TTPi’s aim to be a leader in providing power electronic solutions for integrated drives in automotive applications.

OCTOPUS PROJECT INNOVATIONS

PROJECT APEX – SOWING THE SEEDS FOR OCTOPUS

• Magnet-free, ultra-high-speed motor designed for E-A xle integration

APEX was AEM’s first Innovate funded programme focused on proving the performance and sustainability of its SSRD technology. The project was driven by AEM and Bentley Motors, as the car manufacturer looks to transform its range of vehicles over the next ten years to become more sustainable. SME and TTPi were the other two project partners on APEX. While the cost-effectiveness and sustainability of its SSRD motor technology was already proven, APEX was the first opportunity for AEM to demonstrate the technology could deliver world-class performance. APEX also saw AEM developing a further ten new innovative ideas with a viewing to patenting these in the future to continue driving SSRD forward.

• Integrated power electronics converter technology • Lightweight, high stiffness gear for high-efficiency transmission • Compact integrated thermal management solutions • New wire material solutions for motor windings • New test protocols and facilities for testing component, sub-system and system-level solutions

UNIVERSITY OF BATH PROJECT OCTOPUS PARTNER PROFILE The Institute for Advanced Automotive Propulsion Systems (IAAPS) from the University of Bath is based at the Bristol and Bath Science Park. It is a world-leading centre of excellence for research, innovation enterprise and education, supporting the future direction of the automotive propulsion industry. IAAPS deploys state of the art propulsion systems modelling and simulation tools and techniques in parallel with the latest experimental validation facilities and processes to help industrial partners develop next-generation propulsion technologies with academic insight.

According to IAAPS, the benefits from collaboration with AEM on PROJECT OCTOPUS include:

IAAPS’s role in the OCTOPUS project is twofold. Firstly, advanced multiphysics simulation tools support the development and optimisation of the e-axle, particularly around simulating transmission efficiency and NVH. IAAPS’s second role is in final solution validation, where it is testing the developed e-axle on its new powertrain research facilities to demonstrate range, efficiency and NVH characteristics.

• A bility to disseminate research from the project in public domain.

As with all partners on the project, collaboration with AEM is fundamental to how the team works at IAAPS. The institute’s mission is based on collaboration, and its works this way on a broad range of commercial, IUK and APC projects. Through this project, the institute is gaining exposure to new and innovative technologies and many new partners, including a new original equipment manufacturer (OEM), and thus broadened its collaboration base. The expectation is that IAAPS will continue working with these partners in future projects due to the exposure.

• E xposure to new engineering challenges and solutions • E xposure to new and advanced technologies from all partners. • Demonstration of our research expertise to new engineering partners. • A bility to grow and develop new research relationships with the project partners

“

AN INNOVATIVE PROJECT TO ENGAGE WITH. IT IS GREAT TO BE WORKING WITH BENTLEY, AEM AND THE OTHER PARTNERS TO DELIVER AN ADVANCED LOW CARBON PROPULSION PRODUCT REQUIRING BOTH HIGH PERFORMANCE AND HIGH REFINEMENT.” Professor Sam Akehurst, Deputy Academic Director, IA APS

TALGA PROJECT OCTOPUS PARTNER PROFILE Talga is a European battery anode and graphene additives supplier offering advanced materials critical to its customers’ innovations and the shift towards a more sustainable world. Talga’s role in the OCTOPUS project is to manufacture and supply graphene for an aluminium-based solution that aims to outperform and ultimately replace the copper windings currently used. The improved motor windings are aligned with the project’s aim of developing next-generation lightweight, high-performance component systems that integrate the latest advanced materials and manufacturing techniques.

PROJECT OCTOPUS offers Talga an exciting and challenging opportunity for proof-ofconcept development of new materials to be used in high-performance electric motor windings. Upon success, this project will open a new market for Talga, with multiple use cases envisaged for these materials. The OCTOPUS consortium includes the full value chain, from material suppliers to automotive endusers, which is particularly attractive for developing disruptive technologies such as a new high-tech composite material. The team at Talga believe that the new technology developed here has a strong chance of large-scale utilisation in the future.

“

WE’RE EXCITED TO BE PART OF THE FUTURE OF SUSTAINABLE TRANSPORT. Working with AEM on OCTOPUS allows us to explore an exciting composite material concept for the electric vehicles of the future. It would be a major success to enable aluminium with Talga graphene to outperform copper successfully. As a company, we are excited to be part of the future of sustainable transport and are thankful for the Innovate UK support enabling this work.” Dr Anna Motta, Head of Advanced Materials and Technologies, Talga

OTHER PARTNERS DIAMOND LIGHT SOURCE

HARTREE

Diamond Light Source is the UK’s national synchrotron science facility, located at the Harwell Science and Innovation Campus in Oxfordshire. Operating like a giant microscope, it harnesses the power of electrons to produce bright light scientists can use to study everything from fossils to viruses. It is a not-for-profit limited company funded as a joint venture by the UK Government through the Science & Technology Facilities Council (STFC) in partnership with the Wellcome Trust.

The Hartree Centre is a centre within the Science and Technology Facilities Council (STFC), part of UK Research and Innovation. Hartree is home to some of the most advanced computing, data and AI technologies in the UK. Its experts work with start-ups to global corporations, industry and the research community to tackle realworld challenges to accelerate the adoption of high-performance technologies.

As part of PROJECT OCTOPUS, Diamond Light Source provides access to its state-of-theart research facilities and offers support from a dedicated team of industrial scientists.

Hartree brings its expertise in producing a ‘virtual electric motor’ simulation framework as part of PROJECT OCTOPUS. www.hartree.stfc.ac.uk

www.diamond.ac.uk

PROJECT ELECTRA

DELIVERING SUSTAINABLE AND RELIABLE ELECTRIFICATION OF AGRICULTURAL VEHICLES

AEM and CNHI are driving electrification in farming to reduce environmental impact and optimise production. Here’s how they are doing it. Agriculture is one of the largest industrial producers of greenhouse gases. Therefore, the journey to net zero in farming and agriculture will not be a single step. Instead, it will involve a series of steps to edge the industry closer to zero carbon emissions.

Governments and industry are looking to develop more sustainable food production. At the same time, they are dealing with the threat of market instability and climate change. Addressing the challenge goes to the heart of sustainability in food production. The electrification of agriculture is the ultimate test for the electrification industry, and it’s the challenge AEM is tackling with PROJECT ELECTRA.

THE OPPORTUNITY The agricultural vehicle sector is looking for a breakthrough in electrification. By delivering an integrated, costeffective hybrid powertrain optimised for the agricultural sector’s needs, ELECTRA will help AEM make the UK a leader in electrification for agriculture. Having secured funding of £2.7 million from the Office of Low Emissions Vehicles to explore the opportunity, PROJECT ELECTRA brings together research in electric machine design and vehicle control unit development. With mechanical powertrain systems design and integration expertise, the partnership will deliver a breakthrough in the electrification of the agricultural vehicle sector. PROJECT ELECTRA touches every aspect of the journey to zero carbon food production. From moving hay bales to delivering food to retailers and distributors, it dramatically extends the envelope of how much electrification can be used on a farm. There is also an opportunity to de-risk the existing mechanical process and secure crop density and food supply. Currently, the systems used represent a risk, with hydraulic transmission reliant upon oil. An oil leak during harvesting or sowing may mean the removal of entire fields from crop usage for up to two years. With electrification, this risk disappears. Shifting away from these systems and towards electrification helps secure the livelihoods of farmers and the availability of crops and mitigate the cost variation and issues with availability of oil which are sure to continue into the future.

THE AGRICULTURAL CHALLENGE ELECTRA is one of the most challenging projects in terms of electrification. The primary issue comes with the high use cycles in the agricultural industry. While a consumer vehicle sits idle for most of the day, heavy-duty agricultural vehicles need to be in service constantly. Agricultural vehicles may be used for up to 16 hours every day during sowing and harvesting periods. Lack of reliability has a significant and immediate cost impact on the income and security of our food sources. That’s why a solution has to be practical and credible for the industry that demands reliability.

THE FUTURE OF AGRICULTURE The idea of the future of agriculture is a number of components: A.I. – use of apps to identify crops that need attention, predict weather forecasts, etc. Automation – tractors to be driven by automated technologies (linking to A.I.) Electrification – our focus, making sure the agricultural industry is not left behind with the opportunities of electrification

WHAT AEM IS DOING ELECTRA delivers a comprehensive electrification strategy to achieve significant improvements in performance and sustainability by addressing the unique challenges of electrifying agricultural vehicles. The solution focuses on three elements: • Removing rare earth materials from the process • Improving the recyclability of materials used, and • Utilising existing manufacturing while increasing efficiency, performance and reducing costs PROJECT ELECTRA is focused on developing magnet-free motor technology to drive the systems to replace mechanical or hydraulic systems while retaining performance needs. As well as removing magnets from the systems, the project looks to utilise the latest wire technology,

including replacing copper windings with aluminium to reduce cost and improve recyclability. The scope also looks to reduce environmental impact through the manufacturing process. AEM is delivering an innovative design for manufacture, recyclability and reuse to maximise production readiness. Integration and customisation are critical to the agricultural industry alongside safety. The development of a cost-effective VCU and integration strategy with existing hardware and software to meet safety standards will be complemented by flexible “app-based” functionality to support integration with the wider powertrain. An interface enabling a range of apps based on the agricultural sector’s requirements will allow users to optimise efficiency and use precision agriculture analytics for maximum crop yield and quality.

PROJECT ELECTRA INNOVATIONS • System-level analysis and design to identify and maximise the benefits of electrification • Further cost reduction and improved recyclability to the APEX motor through design for manufacture and the replacement of the copper windings with aluminium • A cost-effective VCU for vehicle manufacturers to incorporate ISO 25119 for off-highway or ISO 26262 for on-road • A flexible interface for a range of apps designed to optimise system efficiency and utilise precision agriculture analytics • Virtual system-level testing at the earliest stages of development

PROJECT PARTNERS

CNH INDUSTRIAL

SEMIKRON

The lead partner on PROJECT ELECTRA is CNH Industrial, home to some of the world’s most innovative agricultural machinery brands.

SEMIKRON is one of the world’s leading manufacturers of power modules and systems primarily in the medium output range (approx. 2 KW up to 10 MW). Founded in 1951 and headquartered in Nuremberg, Germany, the business has approximately 3,000 staff working across 24 sites globally.

The company’s agricultural brands include Case IH, New Holland Agriculture and Steyr for tractors and farming machinery. Its leadingedge technology helps increase the economic viability of farming, maximise density and ensure crops are harvested in optimal commercial conditions. Their AI-powered, self-driving tractors can be programmed to pick crops in ideal conditions, whether to avoid or take advantage of weather or optimal commercial conditions. CNH Industrial has been the leader in the prestigious Dow Jones Sustainability Indices, World and Europe for machinery and electrical equipment for the last decade. CNH Industrial is also home to commercial vehicles brands, such as Iveco trucks and buses, offering further scope for application across these areas. Motor, transmission, PE, VCU hardware/ software designs and simulations will apply beyond agriculture to the off-highway, low-volume commercial vehicle and passenger car market.

SEMIKRON’s products are at the heart of modern energy-efficient motor drives and industrial automation systems. Further application areas include power supplies, renewable energies (wind and solar power) and electric vehicles (private cars, vans, buses, lorries, forklift trucks, and more). In the drive to reduce global energy demand, SEMIKRON’s innovative power electronic products enable its customers to develop smaller, more energy-efficient power electronic systems. As part of ELECTRA, SEMIKRON is supporting the PE design and integration. www.semikron.com

www.cnhindustrial.com

UNIVERSITY OF BATH PROJECT ELECTRA PARTNER PROFILE The Institute for Advanced Automotive Propulsion Systems (IAAPS) from the University of Bath is based at the Bristol and Bath Science park. It is a world-leading centre of excellence for research, innovation, enterprise and education, supporting the future direction of the automotive propulsion industry.

collaboration base. It expects to continue to work with many of these partners on future projects. For IAAPS, a key benefit of engaging in PROJECT ELECTRA is developing an in-depth understanding of the opportunities and challenges in hybridisation/ electrification of heavy-duty vehicles. Other benefits include exposure to new and advanced technologies from all partners and demonstrating its research expertise to and develop new relationships with project partners. www.iaaps.co.uk

IAAPS deploys state of the art propulsion systems modelling and simulation tools and techniques in parallel with the latest experimental validation facilities and processes to help its industrial partners develop next-generation propulsion technologies with academic insight. IAAPS role in the ELECTRA project is initially simulation and control based. IAAPS is carrying out the system modelling of the tractor, motors, inverters, battery and control system to establish the potential benefits of hybridisation in an offhighway vehicle. In addition, IAAPS will develop the high-level control strategy to integrate the driveline components in the most efficient manner. Finally, IAAPS staff will support the rig and field validation of the tractor performance. Collaboration with AEM is fundamental to how IAAPS works alongside all its partners, with its mission based on collaboration across its range of commercial projects. Through ELECTRA, IAAPS has gained exposure to new and innovative technologies and several new partners, including a world-leading offhighway vehicle manufacturer, broadening its

“ HAS ENABLED US TO UNDERSTAND THE OPPORTUNITIES IN HYBRIDISATION. Working with a leading off-highway vehicle manufacturer and AEM, this exciting project has enabled IAAPS to understand the opportunities and challenges in the hybridisation of heavy duty vehicles whilst further developing our modelling and system integration capabilities.” Prof Rob Oliver, Engineering Director, IA APS

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WILL HELP EXPLOIT THE ADVANTAGES OF ELECTRIFICATION WITHIN OFF-HIGHWAY. WORKING WITH THE DIVERSE RANGE OF PARTNERS ON ELECTRA HAS BEEN AN EXCELLENT OPPORTUNIT Y TO INVESTIGATE THE POTENTIAL BENEFITS OF DRIVELINE HYBRIDISATION FOR OFF-HIGHWAY VEHICLES. THE DEVELOPMENT OF DRIVELINE MODELS AND POWER MANAGEMENT STRATEGIES, OPTIMISED FOR T YPICAL DRIVE CYCLES, WILL HELP LEAD PARTNERS TO EXPLOIT THE ADVANTAGES OF ELECTRIFICATION WITHIN THE OFF-HIGHWAY SECTOR IN THE NEAR FUTURE.” Rob Cherry, IA APS researcher IA APS

SR TECHNOLOGY INNOVATIONS PROJECT ELECTRA PARTNER PROFILE

SR Technology Innovations (SRTI) specialises in electronics design, software engineering and technology integration for vehicle applications. The company focuses primarily on control systems, new drivetrain developments, bespoke testing, data acquisition and digital communications technologies.

SRTI has developed new vehicle control unit hardware, and it is continuing to extend its product range in this area. The aim is to have a range of hardware platforms with an architecture that allows SRTI to innovate new control strategies quickly throughout the project while still meeting essential requirements, such as functional safety.

SRTI is equipped for electronics and mechanical design projects, including electronic test equipment, an engine/motor test cell and an engineering workshop with CNC machining capability, supporting test rig and prototype component manufacture.

www.sr-technology.eu

SRTI’s vehicle project experience covers both electric and hybrid vehicle technology integration and also work with alternative fuels. Digital communications projects have included the implementation of V2X protocols and remote vehicle data acquisition. Within PROJECT ELECTRA, SRTI is responsible for designing and manufacturing a hybrid control unit (HCU). It has also used its experience to assist with vehicle simulations to determine which transmission architectures best suit each application. Supporting the vehicle integration of the new hybrid technologies is also part of its role. Working alongside AEM, SRTI has increased its portfolio of electrification and hybridisation projects with a range of vehicle projects and other industrial applications. The task of integrating a combination of new innovative drive components within a vehicle drivetrain is challenging and is reliant on a good control solution to make it work. Through the diversity of projects, SRTI has developed approaches to analysing requirements and developing the necessary control system hardware and software to get the desired performance for each application.

“ INTEGRATING INNOVATIVE TECHNOLOGIES INTO A VEHICLE DRIVETRAIN IS CHALLENGING. INTEGRATING NEW INNOVATIVE TECHNOLOGIES INTO A VEHICLE DRIVETRAIN IS CHALLENGING AND REQUIRES A WELL-DESIGNED CONTROL SYSTEM TO MAKE IT EFFECTIVE. Tim Scott, Managing Director, SR Technology Innovations Ltd

PROJECT CYGNUS

S U C CE S S F UL LY D O W N S I Z ING CORE POWER ELECTRONICS WHILE IMPROVING PERFORMANCE

With PROJECT CYGNUS, AEM is at the forefront to reduce the footprint of core power electronics while maintaining performance. When it comes to downsizing motors, AEM is a leader. AEM continually works to develop motors to be as power dense as possible. Yet, there is a lot further to go in minimising the footprint of manufacture and reducing waste. PROJECT CYGNUS marks the first stage of minimising the footprint around the unique motor technology. The project is focused on how to downsize equipment while maintaining performance.

THE OPPORTUNITY There are many opportunities for high performance, low weight, high power density solutions in sectors, such as motorsport, high-end vehicles, niche commercial vehicles and aerospace. Even for sectors, like commercial vehicles, that don’t benefit from a high-performance, lightweight power electronics (PE) solution, there is an opportunity to develop a rewound, lower-rated version. There have also been significant expressions of interest in the technique of bonding a plastic cold plate by MBDA, Turbo Power Systems and NGK Photonics. PROJECT CYGNUS also has wider benefits across the technology spectrum, with a significant transfer of knowledge between academia and industry. The outcomes also have the potential to make a significant impact in many industries by accelerating the uptake of wide-bandgap technology.

THE OP TIMISATION CHALLENGE The challenge facing the industry is the limitations of silicon. Silicon wafer devices have hit the limit of processing power for their size. For the CYGNUS project, we’ve not focused on the element we already do. Our focus is on reducing the impact of all the parts that go together with the motor. With the current design occupying a 280mm x 180mm footprint, the challenge is to optimise the DC link cap, busbar, and plastic cold plate to reduce footprint and height while still delivering an effective thermal package.

KEY DELIVERABLES • A TRL6 motor controller meeting the 100kVA/ litre target and mature enough for an OEM to apply the technology • A TRL6 SR motor supporting 600V and 800V architectures of buses and high-performance EVs • A core PE block with many applications where size and weight are crucial factors

WHAT AEM IS DOING The motor was already almost the smallest. Now, PROJECT CYGNUS focuses on working on all the parts around the motor to reduce impact and footprint. Using the latest thinking in electronics, the PROJECT CYGNUS design looks to use Wide-bandgap technology to downsize and reduce footprint while driving up efficiency and maintaining performance.

A magnetic sensor will be integrated into the busbar structure to remove the need for a sizeable magnetic core. This innovation reduces volume, improves system operations at elevated temperatures, and simplifies the circuits. The project aims to develop a motor controller and SR machine to interface with the core PE to prove its application.

The core power electronics have been developed from a set of components - proved together in principal - and a plastic bonding cooling system.

PROJECT CYGNUS INNOVATIONS • Use of small footprint, transfer-moulded SiC modules to reduce volume • Use of composite plastic water-cooling structure to reduce weight and volume • Use of bonding to connect the module and cooling structure to reduce manufacturing costs • Use of >800V DC link for the SR motor to increase power density • Integration of a magnetic sensor into the busbar structure to reduce volume and improve the system operations at elevated temperatures • High switching frequency capability improves fine motor control and insulation performance • Use of SR motor to reduce drive train material costs

PROJECT PARTNERS PPM

Pulse, Power & Measurement Ltd (PPM) has been a leading UK specialist distributor of components and systems for high voltage, pulsed power and power electronics since 1994. PPM’s role in PROJECT CYGNUS is to work on the optimisation of the mechanical arrangement using thermal simulation and electromagnetic tools, specification of an optimised DC link cap, validation testing, commission of the critical components and assembly and testing of samples. ppmpower.co.uk

EDRIVE

eDrive Engineering provides innovative solutions to the electric drive sector, specialising in electrical machine development and system integrations to OEM standards. The UK-based company combines our cutting-edge, in-house eMachine optimisation techniques with practical production and validation expertise. On PROJECT CYGNUS, eDrive’s role is developing the controller to drive the PE block, integrating the motor controller and machine, and optimising the package. edrive-engineering.com

COVENTRY UNIVERSITY /SWANSEA UNIVERSITY

PROJECT CYGNUS also benefits from the participation of the teams at the prestigious Coventry University and Swansea University. The involvement of these academic institutions as part of the project will be focused on the simulation, design and fabrication of the magnetic sensors. www.swansea.ac.uk www.coventry.ac.uk

CSA CATAPULT

The Compound Semiconductor Applications (CSA) Catapult is a not-for-profit organisation headquartered in South Wales. Its focus is on accelerating the adoption of compound semiconductors and bringing applications to life in three technology areas: Power Electronics, RF & Microwave and Photonics. The organisation exists to help the UK compound semiconductor industry grow and works across the UK within a range of industry sectors from automotive to medical and from digital communications to aerospace. Its role in PROJECT CYGNUS, CSA Catapult, will be supporting the optimisation of the core power electronics. csa.catapult.org.uk

PROJECT RARE

MAKING RARE EARTH MATERIALS AS SUSTAINABLE AS POSSIBLE.

Magnet recycling has long been a goal of the motor industry. Discover how AEM is making rare earth materials as sustainable as possible.

THE RARE EARTH CHALLENGE

Vehicles use a lot of magnets. Magnets are rare materials that take a considerable toll on the earth when extracted but they cannot be effectively recycled after use.

Magnets are a crucial component in motor vehicles. There are a considerable number of individual magnets in the nondrive mechanisms in a car.

PROJECT RARE set out to answer the question: how do we take rare earth materials and turn them back into magnets used in motors and make them sustainable?

Many of these magnets are tiny, so it’s not easy to replace these with magnet-free technology.

THE OPPORTUNITY

In these situations, the question shif ts to: how do we make these irreplaceable magnets as sustainably as possible?

There are currently no motor designs on the market using recycled rare earth materials. Aside from PROJECT RARE making this a first, there are broader opportunities from the project’s outcome. The scrap separation process has applications with global waste handling and waste handling facility designs. Scrap processing and magnet manufacturing models will benefit recycled rare earth production facilities and can be used in production applications. The materials and manufacturing processes are also applicable across several sectors. On a broader scale, the outcomes from RARE will produce an opportunity to create a competitive advantage for UK motor manufacturing. This would be realised by developing a differentiated supply chain for motors and PE, which is expected to grow to £5bn by 2025. Cost-effective production of magnetic materials could turn the UK into an exporter of magnets for tractions motors and protect the UK from future supply issues.

For all the time and ef for t invested, recycling rare ear th materials has been broadly unsuccessful. The current process is to melt magnets back to a master alloy or use solvent ex traction to ex tract rare ear th materials. These processes are energy-intensive, complex and expensive. They also require magnets to be separated from other components in the motor housing. The need to ex tract and separate magnets from their housing is a significant limitation. The cost means mining is still more cost-ef fective, despite magnets becoming increasingly limited. Therefore, it now makes sense for manufacturers to look for a more practical and cost-ef fective way of operating systems previously used by magnets.

WHAT AEM IS DOING Working with the leader in magnet recycling and manufacturing, Hypromag, at the University of Birmingham, the partnership under PROJECT RARE will look to broaden the range of scrap for the extraction of magnets and scaleup extraction and recycling processes. The University of Birmingham developed its patented Hydrogen Processing of Magnet Scrap method for use with neodymium iron boron (NdFeB) magnets. This process reduces these types of magnets to a demagnetised powder that can be mechanically removed from a component. The powder is purified and remanufactured by resintering, where it is compacted into a solid form using heat or pressure.

This solution allows the extraction of magnets from a wide variety of sources, from automotive applications to loudspeakers and HDDs. This leads to being able to scale up the extraction and recycling process. Prototype motor designs have also been optimised to use recycled rare earths while meeting exacting performance and reliability criteria. Recycled motors will be used in the new auxiliary motors by AEM and applied by Bentley Motors. Unipart will then develop a scalable manufacturing route for the volume production of the design.

RARE PROJECT INNOVATIONS • A demonstrable route to recycle rare earth materials from multiple sources • Motor designs optimised to use recycled rare earths and are recyclable • Prototype motors • A scalable motor manufacturing facility design.

PROJECT PARTNERS

HYPROMAG PROJECT RARE PARTNER PROFILE HyProMag Ltd was founded in 2018 by four original directors David Kennedy, Rex Harris, John Speight and Allan Walton. The company aims to develop a full recycling supply chain for rare earth magnets based upon neodymium iron boron (NdFeB). HyProMag has licensed the patented technology called HPMS (Hydrogen Processing of Magnet Scrap) developed in the Magnetic Materials Group (MMG) at the University of Birmingham. This patent and related Intellectual Property is at the core of HyProMag. HPMS is a hydrogen-based process that can extract NdFeB magnets from electrical products such as hard disk drives.

On RARE, AEM and HyProMag are aligned in their shared beliefs of sustainable manufacturing. RARE enables technological advancements for both HyProMag and the wider consortium, developing products with a much lower embedded carbon level than permanent magnet motors using virgin rare earth magnets. According to the company, involvement in RARE will be hugely beneficial to its growth. As a young company, the ability for HyProMag to showcase its recycled magnets in prestigious applications gives it commercial credibility that would otherwise be difficult to achieve in such a small timescale.

HyProMag is involved with scaling the laboratory trials of the HPMS process and making sintered magnets from powders that have been extracted, purified and processed from end of life magnet scrap. Proving the quality of the short loop recycling method is central to the company’s goals as part of RARE.

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AN ESSENTIAL STEP FOR THE UK’S SUPPLY CHAIN IN THE FUTURE. RARE IS IMPORTANT TO SHOWCASE THE PROPERTIES OF RECYCLED MAGNETS IN A SIGNIFICANT AND PRESTIGIOUS MOTOR APPLICATION. THIS IS AN ESSENTIAL STEP NOT ONLY FOR US AT HYPROMAG BUT ALSO FOR THE UK’S SUPPLY CHAIN IN THE FUTURE.” Nick Mann, Operations General Manager, HyProMag

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A DEEPER UNDERSTANDING OF THE IMPORTANCE OF SUSTAINABILITY...

UNIPART GROUP PROJECT RARE PARTNER PROFILE Unipart Powertrain Applications (UPA) is one of the largest UK-based Tier 1 automotive partners with extensive manufacturing production expertise. UPA is part of the wider Unipart Manufacturing Group that delivers tailored solutions to critical manufacturing, engineering and supply chain problems. Through its collaboration with Coventry University, Unipart is leveraging the extensive R&D workshop facilities of the Institute for Advanced Manufacturing and Engineering and the opportunity to draw on the expertise of Coventry University, recognised academic leaders in manufacturing technology. As a result, UPA has successfully delivered and exploited multiple IUK-supported projects. UPA is developing high volume production facility designs, optimising key process steps to support cost-effective scale up (circa 100K units per annum) of motor designs. As one of the largest UK based Tier 1 automotive partners, Unipart is a recognised volume automotive supplier that supplies globally. As an experienced partner in APC and Innovate UK programmes, Unipart has a strong track record of converting research into commercial opportunities. The latest example is Hyperbat, a joint venture with Williams Advanced Engineering to deliver electric vehicle batteries to market. AEM and UPA are working together to develop the best e-motor design for mass production, focusing on efficient assembly techniques and recyclability.

of UPA’s role in developing the manufacturing facility, Unipart is working closely with AEM to optimise the design for ‘Design for Assembly’. For UPA, the production of e-motors is a new venture and a significant opportunity. By developing skills acquired for the Hyperbat battery production facility, UPA can move forward in producing and distributing components for the electric vehicle market. As the demand for Hybrid and fully electric vehicles continues to grow, the opportunity for UPA is to build its portfolio in this market and become a critical 1st tier supplier.

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WORKING WITH AEM ON THE RARE PROJECT HAS GIVEN ME A DEEPER UNDERSTANDING OF THE IMPORTANCE OF SUSTAINABILIT Y FOR THE FUTURE AND HOW WE CAN WORK TOGETHER TOWARDS A CARBON-NEUTRAL ENVIRONMENT THROUGH THE DEVELOPMENT OF ELECTRIC MOTORS” Darren Herbert, Research, Design and Development Engineer, Unipart Powertrain Applications

AEM is supporting UPA with initial benchmarking and research support for electric motor manufacture, a study that is still ongoing. Moving forward, AEM is providing the design of a chosen e-motor for the RARE project. As part

OTHER PARTNERS BENTLEY MOTORS PRO JEC T R ARE

PARTNER PROFILE

Bentley Motors’ participation in RARE enables the company to identify potential alternative supply routes for sustainable motors and drives throughout the vehicle and enable to design and manufacture of bespoke motors for niche applications from a UK supply base. Furthermore, the collaboration with AEM shows Bentley Motors is strongly committed to electrification and sustainability by collaborating with leading academic and commercial partners. Involvement in RARE also gives Bentley the opportunity to identify ways to utilise the IP being developed in other applications within the vehicle.

INTELLIGENT LIFECYCLE SOLUTIONS PRO JEC T R ARE

PARTNER PROFILE

Intelligent Lifecycle Solutions (ILS) is global electronic reuse and recycling expert. Trusted in the UK by top PLCs and government institutions and in the US by Fortune 500 companies, ILS processes redundant e-waste through material recycling, value recovery and reuse, repair and recycling of technology for parts. ILS’s role with PROJECT RARE is to establish the scrap evaluation and selection process, design the scrap separation process, build a process demonstrator, and supply the scrap material. lifecyclesolutions.net

UNIVERSITY OF BIRMINGHAM PRO JEC T R ARE

PARTNER PROFILE

The University of Birmingham is a leading institution in researching and developing solutions for the recycling of rare earth magnets. The university is home to the Magnetic Materials Group, the only group in the UK focused on processing and recycling permanent rare earth materials. As part of PROJECT RARE, the University of Birmingham’s role is identifying recycled material characteristics, supporting HyProMag to design and simulate the scrap processing facility and magnet production process and supporting HyProMag to build the process demonstrators. www.birmingham.ac.uk/research/activity/ metallurgy-materials/magnets/index.aspx

PROJECT SANGREAL

DEVELOPING A LOW-COST VEHICLE ELECTRIFICATION SYSTEM READY FOR MASS PRODUCTION IN 2021.

AEM AND TEVVA ARE AT THE FOREFRONT OF THE UK’S COMMERCIAL VEHICLE ELECTRIFICATION DRIVE WITH THE GOAL OF EXTENDING THE RANGE OF BRITAIN’S COMMERCIAL VEHICLES THROUGH OPTIMISED POWER TRAIN SYSTEMS. 56

Like many developed economies, Britain relies heavily on its network of large commercial vehicles. Entire supply chains are dependent on the reliability and performance of this network. Already, AEM has successfully integrated a more sustainable motor into large commercial vehicles. Yet, we know we can make considerable improvements to develop the next generation of motors for even larger commercial vehicles. Working with long-term partner Tevva Motors, the SANGREAL project is focusing on developing a low-cost vehicle electrification system ready for mass production in 2021.

THE OPPORTUNITY Despite there being a clear need, the landscape is relatively sparse for possible solutions to the challenge. Currently, no other companies offer a magnet-free solution comparable to what AEM offers. Furthermore, in Europe, there are no commercially available competitors in the 7.5-14t range of vehicles. The SANGREAL project timeline for having a system ready for mass production looks to serve multiple OEMs with an electrification solution for current and future model ranges.

THE COMMERICAL VEHICLE CHALLENGE The key challenges around electrification in commercial vehicles revolve around three issues: • Range anxiety • I nability to meet all duty cycles • Charging infrastructure To accelerate the drive towards electrification in commercial vehicles, there is a need to meet these specific challenges by developing a complete EVE drivetrain solution. This would need to deliver greater operational range, less weight, increased reliability and a reduction in costs through the supply chain.

WHAT AEM IS DOING The approach through SANGREAL is to develop a complete low-cost system comprising a drive system, battery pack, optional range extender, and control system to target the logistics market.

One of the critical innovations in commercial vehicles has been replacing copper windings — which are particularly difficult to recycle — with aluminium windings. These offer the same level of performance but with greater sustainability.

Within a truck, our focus is how we optimise transmission design. It’s not just about making the most efficient motors globally; AEM is focused on building upon current IP to develop the most efficient power train. By optimising the HDSRM motor design, we can minimise package and weight and optimise performance.

The use of innovative gear manufacturing processes also significantly reduces the size and weight of the transmissions.

Tevva brings its vast experience and expertise to the project as it looks to build upon its IP to improve the modularity and packaging of its high voltage traction batteries. Tevva has also developed a new ‘transaxle’ solution and next-generation range extender, both of which will be ready for integration, mass production and end-of-life.

As we scale our technology upwards to support 19-ton vehicles, AEM maximises sustainability and durability across different platforms. Our progress on SANGREAL shows AEM isn’t standing still and continues to focus on even broader applications of the technology in the future.

TEVVA MOTORS PROJECT ELECTRA PARTNER PROFILE

Essex-based electric truck company, Tevva Motors has partnered with AEM to develop and co-create sustainable technology for use in its existing and future product range and gain a clear competitive advantage. Tevva is an electric truck company leading the drive to zero-emission freight, with a spectrum of options for high efficiency, zeroemission medium- to heavy-duty trucks. The company’s revolutionary range extension technology allows its vehicles to do all the work of a diesel vehicle, with total peace of mind about range and environmental impact. The company has vehicles on the road already, getting the job done, and is focused on optimizing H2FC integration into their solution. As the lead partner for the SANGREAL project, Tevva has responsibility for all vehicle development-related activities.

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The firm’s involvement in the project will help to accelerate the development of Tevva’s fuel cell range extended 7.5t-19t Battery Electric Vehicles for zero-emission urban freight. The development of sustainable product technology is of key importance to Tevva and collaboration with AEM provides Tevva with access to class-leading rare-earth motor technology which it believes will offer a distinct advantage over its competitors. Co-creation with AEM enables Tevva engineers to embed the motor technology within its product range at an early stage, this integrated approach offers clear benefits. SANGREAL provides Tevva with a detailed understanding of the core principles of Switched Reluctance motor technology and how its trucks can be designed to optimise efficiency across the operating range. The added benefit of this particular switched reluctance motor is that they are rare-earth metal-free which supports the overall values of Tevva as an OEM.

T E V VA I S L E A D I N G T H E D R I V E T O Z E R O E M I S S I O N S F R E I G H T.

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AN OPPORTUNITY TO STRENGTHEN OUR COMMERCIAL TRUCK OFFERING.

Working with AEM has provided Tevva with an opportunity to strengthen its commercial truck offering through drive-line innovation based on switched reluctance (SR) motor technology. We believe this will enable Tevva to take full benefit from early technology adoption, enabling first-mover advantage”. Richard Lidstone-Scott, Commercial Director, Tevva

SANGREAL PROJECT INNOVATIONS • Creating a low-cost, mass production-ready system removes the need for traditional rear differential and propshaft and instead uses a modular solution compatible with any chassis length. The additional space holds batteries, improving impact resistance • Stressed member battery packs form part of the chassis, removing the need for separate structures and saving further weight • Cooling allows for smaller batteries without overheating, allowing more flexibility for the end-user to use the rightsized battery for their duty cycle • Operational range extenders with AEM eGenerators remove range anxiety and provide flexibility and range beyond that of a pure EV • AEM motors provide traction, transmitting drive independently from twin motors to the rear wheels. This removes integration challenges by removing the rear differential and increasing efficiency and space whilst reducing costs and weight • The aluminium windings remove the need for copper, improving the supply chain, motor weight and recyclability

WHAT NEXT? WORK WITH US. JAMES WIDMER, CHIEF EXECUTIVE OFFICER AT ADVANCED ELECTRIC MACHINES EXPLAINS WHERE AEM GOES NEXT – AND HOW YOU CAN BE PART OF THE JOURNEY “Our primary objective is to design and develop world-class and truly sustainable drive train technologies. We’re developing this to be used in the commercial market with the first generation of electric trucks and the automotive market looking at second and third generation vehicles coming through and aerospace market. I look forward to the day when the world becomes used to us flying around in electric aircraft and we’re working towards that goal, too. But that’s not all. Our second objective is not just to be a company who develops these technologies. We also want AEM to be a company who makes these technologies as well. We want to manufacture in the North East, locally, and importantly we want to manufacture to high levels of quality. To be recognised as a high quality manufacturer is just as important to us as developing the technology.

Finally, we want to deliver all this as we move towards becoming a world-class business known around the globe for our development and manufacturing capabilities. We believe the UK will become the global centre for electrification and AEM is a key part of this aim. Our goal is to turn Advanced Electric Machines into a business which is recognised globally for its successes.”

Dr James Widmer CEO AEM

WE BELIEVE THE UK WILL BECOME THE GLOBAL CENTRE FOR ELECTRIFICATION AND AEM IS A KEY PART OF THIS AIM.