Higher Efficiency Amorphous Steels in the Drivetrain

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FAULHABER Drive Systems

Taiwan Machine Tool & Accessory Builders' Association (TMBA)

Wuxi InfiMotion Technology Co., Ltd.

With a new type of electric motor based on amorphous steels, the focus is shifting to an adjustment screw that has received little attention to date and could significantly increase the efficiency of electric drives.

While power electronics and semiconductor technologies in particular have developed further in recent years, the material basis of electric machines is now also coming more into focus. Horse Powertrain provides a current example with a new type of electric motor that is specifically designed for use in hybrid drives and relies on amorphous steel in the stator.

Material Innovation As An Efficiency Driver

At the heart of the development is the use of an amorphous steel material. In contrast to conventional, crystalline electrical steel sheets, this material does not have a regular lattice structure. This results in special magnetic properties such as high permeability and significantly reduced remagnetization losses.

Another advantage is the possible material thickness. While conventional electrical sheets are typically in the range of 0.2 to 0.35 mm (0.008 to 0.014 inches), the new motor concept uses layer thicknesses of just 0.025 mm. This drastic reduction minimizes eddy current losses, as these scale quadratically with the sheet thickness.

Significantly Reduced Iron Losses

The use of the amorphous material significantly reduces iron losses in the stator. According to the manufacturer, these losses are reduced by around 50% compared to conventional designs. This has a particularly positive effect on the overall efficiency in the partial load range, which plays a major role in real driving operation. As a result, the developed engine achieves a peak efficiency of 98.2%, making it one of the most efficient engines currently available in the automotive sector. At the same time, the unit delivers a maximum output of 140 kW with a torque of 360 Nm.

Systemic Effects in the Vehicle

Even if an increase in efficiency of a few percentage points may seem small at first, it has measurable effects at vehicle level. In hybrid drives, the higher efficiency of the electric motor leads to a reduction in overall energy consumption. The manufacturer puts the savings in real vehicle operation at around one percent in terms of fuel and energy consumption.

Against the backdrop of increasingly strict emissions regulations, even such a value is relevant, as it has a direct impact on fleet consumption and CO₂ balances. At the same time, the higher efficiency enables better use of electric driving components and an optimized design of the overall system.

Relevance for Hybrid And Range Extender Concepts

The engine is used in particular in hybrid vehicles, plug-in hybrids and range-extended electric vehicles (REEV). In these architectures in particular, it is important that energy conversion is as low-loss as possible, as electrical and combustion engine components are closely interlinked. Reducing losses in the electric motor can not only lower energy consumption, but also reduce thermal loads. This opens up additional degrees of freedom for integration into compact drive systems.

The development shows that, in addition to semiconductors and system architectures, classic components such as electrical machines continue to offer considerable potential for optimization. Materials science approaches in particular could play a greater role in the future. (mr)

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