The principle of today’s electric motors is almost 130 years old. The functioning of all electric motors used to be based on copper coils. The winding of the motor coils in the classic electric drive production represents the most complex step, partly combined with a high degree of manual work. The production is therefore complex, expensive and difficult to scale.
During the design phase, a number of pole pairs is defined that can not be changed after production. This establishes an operating point at which the machine operates optimally, i.e. achieving their maximum efficiency. Electrical machines are so far low-loss energy converters with only one optimized operating point. Apart from that, the efficiencies of conventional electric drives are decreasing enormously. Therefore, the goal should be to achieve maximum efficiency at every operating point.
We believe that after 130 years, it’s time for something new!
ISCAD describes a paradigm shift: 48 V instead of 800 V and aluminum bars instead of copper coils. Every single bar of the stator cage is supplied by a dedicated power electronics unit. The number of pole pairs can be varied. The result is a virtual gearbox.
Another special feature of the construction is the integration of the power electronics in the motor through which an optimal utilization of the machine volume is achieved.
ADVANTAGES OF ISCAD TECHNOLOGY
LOWER MANUFACTURING COSTS
No more stator windings! By eliminating this step, ISCAD is less expensive to manufacture and more efficient. Moreover, the production of high quantities is easier than that with wound electric motors.
NO RARE EARTH MAGNETS
The use of the ISCAD system eliminates the need for rare earths during production. This creates a great independence from global commodity monopolies.
Compared to fixed windings, the ISCAD system offers the possibility of varying the number of poles during operation, thus creating a virtual gearbox that continuously adapts to the load profile.
THE VIRTUAL GEARBOX
The aluminum bars are individually supplied with a dedicated power electronics unit. Compared to fixed windings, the ISCAD system thus has the ability to vary the number of poles during operation. This way MOLABO created the first virtual gearbox in e-mobility.
A large number of pole pairs is selected for high acceleration with high torque demand whereas in rolling operation at constant speed, a smaller pole pair number is used.
Compared to a conventional electric drive, a significantly higher efficiency is possible, especially in the partial load range.
By varying the number of pole pairs and using MOSFETs, significantly higher efficiency can be achieved.
The 48 V technology is intrinsically safe and enables cost saving potentials due to the elimination of high-voltage safety measures.
Due to several aluminum bars in parallel, ISCAD offers enhanced redundancy. In case of failures inside bars or in the power electronics units, the electric drive is still able to operate at slightly decreased performance. No breakdown of the complete system to be worried about!