Under the dual-carbon strategic layout, drive motors, as core components of new energy vehicles, need to pay more attention to the development of high efficiency, miniaturization, and intelligence. In recent years, in order to further improve the core indicators of drive motors such as power density and efficiency and reduce costs, motor companies have continuously developed high-performance motor products, and key materials such as low/no heavy rare earth permanent magnets, 6.5% Si high silicon steel, soft magnetic composite materials, amorphous/nanocrystalline alloys, etc. have received much attention. In addition, although centralized drive is the current mainstream, distributed drive technologies such as wheel-side motors and hub motors have also been a research hotspot because of their advantages such as short transmission paths and independent control of torque between shafts or wheels.
However, the development of new drive motors also faces some problems. For example, some key materials of innovative drive motors still have pain points such as difficult processing and high cost. Distributed drive, especially hub drive, still has problems such as poor controllability, high cost and low reliability. Further verification is needed to promote its application in more vehicle models.
The following mainly discusses two dimensions: advanced materials for drive motors and distributed drives.
Advanced Materials for Drive Motors
The key materials that affect the performance and cost of drive motors include permanent magnets, silicon steel sheets, copper wires, etc. In the future, we need to focus on developing high-strength, low-loss electrical steel and new soft magnetic materials, high-temperature resistant low-heavy rare earth/no heavy rare earth permanent magnets, high-conductivity, low-loss super copper wires, and corona-resistant, high-thermal conductivity insulation systems.
New soft magnetic materials include 6.5%Si high silicon steel, amorphous/nanocrystalline alloys, soft magnetic composite materials, etc. The manufacturing process of 6.5%Si high silicon steel is complex, which leads to difficult quality control, low production efficiency and high cost; amorphous/nanocrystalline alloys have low saturation magnetic density, thin, brittle and hard materials, and difficult processing, and are more suitable for ultra-high speed and high frequency motors.
NdFeB material is still the most important rare earth permanent magnet material. The permanent magnet MQ3 material using Nd-Fe-B rapid quenching and thermal deformation technology is one of the key focuses of new permanent magnet materials. Reducing the amount of heavy rare earth is the current key research and development direction. Grain refinement technology, intercrystalline technology, intercrystalline diffusion technology, and comprehensive technology are the key points of research. In addition, the electromagnetic motor does not need to use permanent magnets, which is also one of the industry's concerns and potential product options.
Distributed Drivers
Distributed drive is an important choice for the future development of electrification, and it will empower autonomous driving. Distributed drive includes key technologies such as torque distribution and control, drive anti-slip control, fault-tolerant control and functional safety. At the same time, since distributed drive still has certain challenges in terms of controllability and cost, it may be first applied to high-end passenger cars and special vehicles (with high performance requirements and insensitive to cost).
Wheel-side motors and hub motors are two important technical routes for distributed drive. Wheel-side motors can give full play to the electromechanical, thermal and magnetic multi-field design advantages of deeply integrated electric drive assemblies to achieve small and lightweight drive motor and reducer assembly systems. Compared with hub motors, wheel-side motors have lower engineering design difficulty, but there are still cost challenges.
Hub motors face multi-dimensional technical challenges such as heat dissipation, sealing, control, and impact resistance. There is still a long way to go before large-scale mass production and application in the passenger car field. Breakthroughs are needed in engineering design and verification such as efficient thermal conductivity and cooling technology, dust and water resistance, low dynamic resistance sealing technology, and integrated corner module technology.
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