Advanced measurement technologies for magnetic materials used in automotive applications Lukasz Mierczak Automotive Workshop “Let´s improve EV performance together” Lüdenscheid, Germany, 8th November 2

Outline: Introduction to Brockhaus Characterisation of soft magnetic materials Brockhaus stators testers Results from case studies on detrimental effects of stamping, welding and housing processes Characterisation of hard magnetic materials under AC magnetisation

Introduction to BROCKHAUS MEASUREMENTS (BMT) soft magnetic Electrical Steel BMT is the leading international specialists for measuring and testing technology for soft and hard magnetic materials. Our state-of-the-art technology is versatile and essential for R&D, incoming goods inspection and quality control. Power Loss Field Strength • Motor designers • Stator manufacturers • Rotor manufacturers • Electrical steel manufacturers • Permanent magnet manufacturers Field Strength Renowned Universities Magnetic Flux hard magnetic ,raT“ Remanence Flux Density Magnetic Moment Temperature Coefficient...

Links between magnetic properties and motor performance BROCKHAUS ACADEMY

Characterisation of soft magnetic materials – Epstein frame Measurement conditions specified in the international standard IEC 60404-2: • Shape of polarization J waveform should be sinusoidal Measurement temperature should be 23°C (+/-5 °C) No external stress exerted on the specimens Epstein measurements under standard conditions are insufficient for proper power loss characterisation of magnetic materials used in automotive applications The measurement conditions should include the following main factors: ➢ Non-sinusoidal magnetisation conditions due to PWM excitation and harmonic distortion...

m Pneumatic cylinders for application of uniaxial load up to 6500N tension and 1500N compression m Cylindrical guides for uniform load application m Embedded potentiometer for load regulation m Embedded load cells for real-time force measurements m Magnetisation under B,H control, PWM or user-defined arbitrary conditions

Characterisation of soft magnetic materials – measurements under applied stress on NO30

Effects of manufacturing on magnetic properties of stator laminations • From Raw Material to End Product phase the material is subjected to different processing influences • At each production stage the magnetic properties are affected • Testing before and after each manufacturing process is necessary to control the quality of production and final product

Brockhaus Stators Testers for back-iron measurements Brockhaus MPG200 measurement system Stator with BST-M measurement coils wound on back iron BST split coil for stator testing

Brockhaus Stators Tester BST-SA for back-iron measurements Double split coil for stator testing

■ Non-annealed stator measured with BST-M • Annealed stator measured with BST-M -A Annealed stator measured with BST-SA (split coil) Non-annea ed stator measured with BST-M Annealed stator measured with BST-M Annealed stator measured with BST-SA (split coil) Magnetic Flux Density B [T] 3.0 Magnetic Flux Density B T Magnetic Field Strength H [A/m] 12

Brockhaus Localized Stator Tester BST-L BST-L sensor head in measurement position

Detrimental effects of stamping, welding and housing processes

G-shaped core made of laminated high-permeability material BROCKHAUS ACADEMY l-shaped core made of laminated high-permeability material with adjustable vertical position for closing the magnetic circuit Permanent magnet positioned for testing B-sensing coil wound directly on permanent magnet for measurement of flux density H-sensing coils for measurements of magnetic field strength in the vicinity of permanent magnets Magnetization coil with variable number of primary windings (N=10, 30, 80,130, 180) supplied

Case study PM – influence of segmentation and EDM cut-outs on AC power loss of permanent magnets Magnet with EDM Snake-line cut Segmented Magnet

Summary: Brockhaus developed a wide range of measurement technologies for advanced characterisation of soft and hard materials used in automotive applications Manufacturing processes, such as stamping, welding and housing have a detrimental impact on magnetic properties of stator cores Magnetic measurements enable optimization of manufactured electric motor components Continuous monitoring of stators quality is necessary for assurance of expected motor performance and driving range of electric vehicles Please register for our newsletter on www.brockhaus.com