a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

a

/// High Performance Motors

Revolutionary Winding Technology

SciMo developed a revolutionary and unique winding technology solving the core problems of any modern electric motor, which are material efficiency, cooling performance and cost. Out motor technology enables electric motors with power densities of up to 17 kW/kg


/// Highest Power Densities

SciMo is producing electric motors with highest power to weight ratios. Our motors proved their potential in the most challenging aerospace and motorsport applications, leading to a world champion title in 2015. An overview of the different motor specifications is given in the following table.
Motors
Pole pairs
Speed (rpm)
Torque (Nm)
Weight (kg)
Power (kW)
Power density (kW/kg)
SY11
1
125.000
0.4
2.0
25
12.5
SY21
2
30.000
18
4.0
50
12.5
SY31
3
20.000
25
5.3
70
13.2
SY43
4
30.000
80
13.0
180
13.8
SciMo SY11 Hochleistungsmotor
SY11
SciMo SY21 Hochleistungsmotor
SY21
SciMo SY31 Hochleistungsmotor
SY31
Wirkungsgradkennfeld des SciMo SY43 Hochleistungsmotors
SY43


/// Motor Technology


/// Winding Technology

SciMo radically rethought the purpose and the properties of an optimal winding for electric motors from scratch. This new approach to coil winding is based on thin rectangular flat wires that significantly increase the copper density in the motors.

The SciMo windig technique enables distributed windings with  copper filling factors above 70%. As a result the power density and efficiency are  significantly improved. Furthermore, the material savings in magnets and electric sheet lamination can compensate for the incresead winding manufacturing costs.

/// SciMo Winding

Distributed winding using rectangular wires:

  • over 70% copper filling factor
  • very good heat dissipation
  • defined location of terminals
  • robust and reliable design
/// Conventional Winding

Distributed winding using round wires:

  • around 45% copper filling factor
  • bad heat dissipation
  • manual phase connection
Motors 3
Motors 4


/// Innovative Cooling Concepts

The continuous power density of electric machines depends mainly on the cooling performance. With a good design of the electric machine and a water jacket cooling it´s possible to achieve continuous power densities well above 5 kW/kg.

  • Winding head geometry optimized for optimal cooling performance
  • Isolated cooling channels inside the slot for single tooth windings
  • Cooling performance increased up to 90%
Motors 5
Motors 6
  • Direct oil cooling of winding heads
  • 4 times increased heat dissipation
  • Detailed CFD and thermal simulation for optimal cooling performance


/// Motor Design and Optimization

SciMo is using a fully automated closed loop approach to design and optimize the electromagnetic layout of our motors. This optimized and detailed simulation of the electric drive system is crucial in order to design motors with highest performance that are close to the physical limits.

The iterative approach to the fully automated simulation toolchain is indicated in the following. The iteration stops when a global maximum is found.

  1. Unique parameter set describes the geometry and materials.
  2. The geometry is generated in high detail.
  3. Fully parallelized electromagnetic FEA is performed.
  4. Generation of a full 3D thermal FEA. Results are simplified to a thermal network of components of interest.
  5. Output motor data can be used to directly optimized inverter and gearbox design for particular machine layout.
  6. The simulation results are evaluated and used as feedback for an optimization of the parameter set to start with the next iteration.

The simulation results or output modell fully characterizes the entire drive system, which can be used to apply loadcycles and calculate the expected thermal response. As well, more complex simulations can be performed, for example calculation the maximum dynamics.

The tool chain is regulary benchmarked against test bench runs with our different motors. Deviations between simulations and measurement results are used as input data to optimized the simulation model.


/// Motor specifications

The following list shows some examples of motors developed by us with performance specifications. We cannot show the customer-specific developed motors at this point.


/// SY11

Motor parameters of the SY11 high speed motor.

Design parameter
Value
Pole pairs
1
Airgap diameter (mm)
20
Active length (mm)
50
Winding
distributed
Magnet config.
buried
Cooling
Water jacket
Status
Prototype
Property
Value
Maximum speed (rpm)
125.000
Maximum efficiency (%)
>94
Maximum power (kW)
25
Continuous power (kW)
5
Continuous torque (Nm)
0.4
Weight (kg)
2.0
Wirkungsgradkennfeld des SciMo SY11 Hochleistungsmotors
Efficiency Map
SciMo SY11 Hochleistungsmotor


/// SY21

Motor parameters of the SY21 motor with highest power density.

Design parameter
Value
Pole pairs
2
Airgap diameter (mm)
40
Active length (mm)
80
Winding
distributed
Magnet config.
buried
Cooling
Oil cooling
Status
Running in application
Property
Value
Maximum speed (rpm)
30.000
Maximum efficiency (%)
96
Maximum power (kW)
50
Continuous power (kW)
32
Continuous torque (Nm)
18
Weight (kg)
4.0
Wirkungsgradkennfeld des SciMo SY21 Hochleistungsmotors
Efficiency Map
SciMo SY21 Hochleistungsmotor


/// SY31

Motor parameters of the SY31 motor with high power density.

Design parameter
Value
Pole pairs
3
Airgap diameter (mm)
60
Active length (mm)
66
Winding
distributed
Magnet config.
buried
Cooling
Water jacket
Status
Running in application
Property
Value
Maximum speed (rpm)
20.000
Maximum efficiency (%)
95
Maximum power (kW)
70
Continuous power (kW)
30
Continuous torque (Nm)
25
Weight (kg)
5.3
Wirkungsgradkennfeld des SciMo SY31 Hochleistungsmotors
Efficiency Map
SciMo SY31 Hochleistungsmotor


/// SY43

Motor parameters of the SY43 motor with highest performance.

Design parameter
Value
Pole pairs
4
Airgap diameter (mm)
80
Active length (mm)
100
Winding
distributed
Magnet config.
buried
Cooling
Water jacket
Status
In Production
Property
Value
Maximum speed (rpm)
30.000
Maximum efficiency (%)
97
Maximum power (kW)
180
Continuous power (kW)
100
Continuous torque (Nm)
80
Weight (kg)
13.0
SciMo SY43 Hochleistungsmotor
Efficiency Map
Wirkungsgradkennfeld des SciMo SY43 Hochleistungsmotors