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The advantage of high power density machines (achieved via increased speed) is the reduction of system weight for a given magnitude of power conversion, allowing compact designs. The UK has positioned itself as a leader in high power density traction motor design and development for vehicle propulsion. In order to reduce the size of these motors whilst increasing the speed and hence power density of the motors, composite elements and novel assembly processes are employed to meet the performance requirements.

These very high power density motors have typically been geared to niche, development volume applications. Demand for these technologies is increasing as the technology is adopted more widely, however there is currently no supply chain within the UK capable of meeting the required volumes efficiently and competitively. Existing supply chains are only capable of delivering low volumes of the required technologies, or high volumes of conventional, lower specification rotors.

The innovation within this project is the upscaling and adaptation of current production technologies to develop a flexible manufacturing process capable of manufacturing high speed permanent magnet radial rotors with composite sleeves, and composite axial rotor plates. The project will review and identify the most feasible solutions for all process steps, from initial machining of rotor shafts, assembly and grinding of the magnets, manufacture of the composite sleeves (radial rotors) or composite rotors (axial rotors), to final assembly and balancing.