GKN Sinter Metals to display innovative Transversal Flux Motor at the CWIEME 2013

5/22/2013 1:00 AM
PM - Soft Magnetic

GKN Sinter Metals is proud to introduce its Transversal Flux Motor at the CWIEME 2013 (Berlin, Germany). The development of this motor is a result of a collaboration between GKN and RWTH University of Aachen. GKN Sinter Metals has successfully demostrated that the use of Soft Magnetic Composite (SMC) materials can allow for the design of  motors featuring smaller dimensions, lower weight and reduced noise. The prototype named “Elektra” is fully serviceable.

In its basic version the motor consists of a stator element, a copper winding and a rotor with permanent magnet. The stators are made of Soft Magnetic Composite (SMC) material consisting of pure iron particles with diameters of less than 0.2 millimeters coated with an insulation layer. Being pressed to the desired shape, the material is cured at temperatures between 600 – 700°C, much lower than the 1000°C commoning used in sintering, in order to not  cause damage to the insulation layer. This insulation layer allows three-dimensional magnetic properties which are absolutely essential for the motor design and effect a significant reduction of eddy current losses. Another benefit provided is the reduction of the copper content therefore less weight and cost compared to traditional radial flux motors. The copper winding along with two identical stator poles in combination with a permanent magnet in the rotor generate a greater toque density. In order to produce a motor with an output of one kilowatt, three phase elements have to be assembled in line with a displacement of 120 degrees each. Higher performance can be achieved with  a modular design of several motors assembled in line. Their frequencies range from 500 Hz up to 30 kHz.

GKN Sinter Metals offers three versions of SMC material. The special properties of the powder and the insulation layer allow specific control of permeability and losses. The three-dimensional stator design approach is free, particularly in axial direction.

Another advantage of the transversal flux motor vs. the radial flux motor is its compact design with as much as 30 percent reduced in size. With only small masses rotating in the rotor supported by axial magnetic forces results in a moter with low-noise.

The development of the transversal flux motor coincides with the growing demand for high-performance electric motors of compact design and low weight. The excellent expert knowledge of GKN Sinter Metals in the development and production of sintered and non-sintered soft magnetic materials offers optimal solutions focused on high cost efficiency and unparalleled engineering in combination with modern materials and processes.

In addition to the Transversal Flux Motor, GKN Sinter Metals will display other products from its portfolio, including sleeve bearings made of sintered metals.

Please visit GKN Sinter Metals at the CWIEME 2013 in hall 1.2, stand 1307 or go to the website www.gkn.com/softmagnetic.

On 04.06.2013 the company presents a technical paper in English titled “New opportunities in the development of innovative, cost and power efficient electric motors through the use of metallurgically produced parts.”

About GKN Sinter Metals

GKN Sinter Metals is the world’s largest producer of precision powder metal products. With a focus on superior delivery, quality and total solutions, the company offers extensive technical expertise in design, testing and various process technologies. GKN Sinter Metals offers a full range of more than 10,000 complex shape, high strength products for automotive, industrial and consumer markets worldwide. The company’s global footprint spans more than 13 countries across five continents. GKN Sinter Metals is in close proximity to its customers with more than 30 global locations and approximately 6,500 employees.

About GKN plc

GKN plc is a global engineering group. It has four divisions; GKN Driveline, GKN Powder Metallurgy, GKN Aerospace and GKN Land Systems, which operate in the automotive, aerospace and land systems markets. Approximately 48,000 people work in GKN companies and joint ventures in more than 30 countries. GKN is listed on the London Stock Exchange (LSE: GKN) and recorded sales of GBP6.9 billion in the year to 31 December 2012.

 Schematic structure of transverse flux motor