Close to 60% of the power generated worldwide, be it through renewable or conventional route, passes through an electric motor to enable the functioning of modern devices such as in Permanent Magnet Synchronous Motors (PMSMs) – an Axial Gap Motor. The key component of an electric motor is the electromagnetic core comprised of stator, rotor, and permanent magnets. The traditional way of making stators and rotors has been to fabricate them from laminated steel sheets rolled by steel mills and then converted into stampings on heavy presses using multiple sets of dies and tools. This is a very labour intensive, polluting, wasteful and time-consuming process. The permanent magnets follow powder metallurgy option to press powder into shaped magnets which again is a lengthy process requiring costly molds. Additive Manufacturing does away with all the fabrication limitations of traditional process and has revolutionised the way rotating electrical motors can be designed and manufactured to improve the efficiency of motors. Multiphysics FEM simulation software is used to predict magnetic field flows, thermal hotspots and mechanical stress points to bring about more efficient outcomes at a fraction of the time. Topology Optimisation (TO) software tools are used to re-engineer the components to reduce weight and volume thereby increasing the torque density. Our innovation increases the efficiency of the motor resulting in energy saving and enhancing sustainability. In an E vehicle application, this translates into much higher mileage from the same one time charge and higher energy generation in a renewable energy application such as a windmill.
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