Altair Case Studies Driving Innovative E-Mobility Development: EVR Motors' New Simulation-Aided E-Motor Topology

	Driving Innovative E-Mobility Development: EVR Motors' New Simulation-Aided E-Motor Topology Altair

Driving Innovative E-Mobility Development: EVR Motors' New Simulation-Aided E-Motor Topology

Altair

Technology Category	Analytics & Modeling - Digital Twin / Simulation Sensors - Electrical Conductivity Sensors
Applicable Industries	Automotive Transportation
Applicable Functions	Product Research & Development
Use Cases	Transportation Simulation Virtual Prototyping & Product Testing
Challenge	The shift towards e-mobility has put immense pressure on the automotive industry to develop more sustainable and affordable transportation solutions. This has led to a rush to electrify products and compete with e-vehicles that match the performance of internal combustion engine models. EVR Motors Ltd., an Israel-based company that designs and develops cost-effective radial flux Permanent Magnet (PM) electric machines, faced a unique challenge. For several decades, motors for electric vehicles have been optimized using the same topology, called Radial Flux Permanent Magnet Motor topology (RFPM). However, EVR chose to take a different approach. Instead of optimizing existing technology, they decided to invent a new topology and develop a completely new type of motor for the electric vehicle industry called the Trapezoid Stator RFPM topology. As the base of EVR topology is different from other well-known motor topologies, the use of multiphysics and optimization tools was highly important. Therefore, the team needed a reliable, robust simulation tool. Read More
About Customer	EVR Motors Ltd. is a new player in the e-mobility industry. Based in Israel, the company designs and develops cost-effective radial flux Permanent Magnet (PM) electric machines for a range of power conversion applications such as renewable energies and vehicle electrification. Established in 2012, EVR initially developed patents for wind turbine generators. However, they adjusted their roadmap when public taste favored e-mobility, and then developed an innovative electric motor called TS – RFPM (Trapezoidal Stator Radial Flux Motor) based on new, patented technology that provides superior power and torque density – all at lower production costs. Read More
Solution	In their quest for a powerful and accurate electromagnetic and mechanical simulation tool, EVR Motors chose Altair® FluxMotor®, Altair® Flux®, Altair® SimLab®, and Altair® HyperMesh®. These tools are part of Altair’s complete solution for electric motor design and were used to simulate their motors before prototyping. Motor development involves numerous design iterations to meet all electromagnetic and NVH requirements. EVR used the Altair tools, particularly the highly flexible Flux software, to improve the simulations so they became more accurate and delivered results close to the real prototypes they were building physically. Today, EVR has achieved a simulation accuracy of about 90%, but they’re aiming to improve this to even higher accuracy of 95-96%. Despite their electromagnetic design being brand new and very different than everything that exists today, Altair’s solutions helped EVR meet this challenge and minimized the number of prototypes while meeting all requirements and saving time. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Digital Twin / Simulation

Sensors - Electrical Conductivity Sensors

Applicable Industries

Automotive

Transportation

Applicable Functions

Product Research & Development

Use Cases

Transportation Simulation

Virtual Prototyping & Product Testing

Challenge

The shift towards e-mobility has put immense pressure on the automotive industry to develop more sustainable and affordable transportation solutions. This has led to a rush to electrify products and compete with e-vehicles that match the performance of internal combustion engine models. EVR Motors Ltd., an Israel-based company that designs and develops cost-effective radial flux Permanent Magnet (PM) electric machines, faced a unique challenge. For several decades, motors for electric vehicles have been optimized using the same topology, called Radial Flux Permanent Magnet Motor topology (RFPM). However, EVR chose to take a different approach. Instead of optimizing existing technology, they decided to invent a new topology and develop a completely new type of motor for the electric vehicle industry called the Trapezoid Stator RFPM topology. As the base of EVR topology is different from other well-known motor topologies, the use of multiphysics and optimization tools was highly important. Therefore, the team needed a reliable, robust simulation tool.

About Customer

EVR Motors Ltd. is a new player in the e-mobility industry. Based in Israel, the company designs and develops cost-effective radial flux Permanent Magnet (PM) electric machines for a range of power conversion applications such as renewable energies and vehicle electrification. Established in 2012, EVR initially developed patents for wind turbine generators. However, they adjusted their roadmap when public taste favored e-mobility, and then developed an innovative electric motor called TS – RFPM (Trapezoidal Stator Radial Flux Motor) based on new, patented technology that provides superior power and torque density – all at lower production costs.

Solution

In their quest for a powerful and accurate electromagnetic and mechanical simulation tool, EVR Motors chose Altair® FluxMotor®, Altair® Flux®, Altair® SimLab®, and Altair® HyperMesh®. These tools are part of Altair’s complete solution for electric motor design and were used to simulate their motors before prototyping. Motor development involves numerous design iterations to meet all electromagnetic and NVH requirements. EVR used the Altair tools, particularly the highly flexible Flux software, to improve the simulations so they became more accurate and delivered results close to the real prototypes they were building physically. Today, EVR has achieved a simulation accuracy of about 90%, but they’re aiming to improve this to even higher accuracy of 95-96%. Despite their electromagnetic design being brand new and very different than everything that exists today, Altair’s solutions helped EVR meet this challenge and minimized the number of prototypes while meeting all requirements and saving time.

Impact #1	Through simulation, EVR developed and tested its new patented motor, which is half the size than some of the industry’s best e-motors. The use of Altair’s solutions allowed EVR to lower the number of prototypes, saving significant time in the development process. Without the Altair solutions, EVR would not have been able to develop their new e-motor in such a short time. The new e-motor was not only lighter than all other motors on the market, it was also more cost-efficient, offering an innovative new smart solution to the highly competitive e-mobility market. This has positioned EVR as a leader in the e-mobility industry, capable of delivering innovative and efficient solutions.

Impact #1

Through simulation, EVR developed and tested its new patented motor, which is half the size than some of the industry’s best e-motors. The use of Altair’s solutions allowed EVR to lower the number of prototypes, saving significant time in the development process. Without the Altair solutions, EVR would not have been able to develop their new e-motor in such a short time. The new e-motor was not only lighter than all other motors on the market, it was also more cost-efficient, offering an innovative new smart solution to the highly competitive e-mobility market. This has positioned EVR as a leader in the e-mobility industry, capable of delivering innovative and efficient solutions.

Benefit #1	Reduced number of prototypes by over 50%
Benefit #2	Reduced weight by up to 50%
Benefit #3	Achieved 90% simulation accuracy

Benefit #1

Reduced number of prototypes by over 50%

Benefit #2

Reduced weight by up to 50%

Benefit #3

Achieved 90% simulation accuracy

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Overview

Driving Innovative E-Mobility Development: EVR Motors' New Simulation-Aided E-Motor Topology

Operational Impact

Quantitative Benefit