Acceleration of cost-effective & scalable manufacturing solution for next generation highly-integrated power electronics, motors & drives

This collaborative project brings together UK design, manufacturing and supply-chain resources to define how future requirements for this innovative solution for an electric motor with integrated power electronics (inverter) will be successfully configured meeting performance, package, cost, quality and volume demands. This feasibility project will robustly set EMPEL and Shield on the accelerated path to class-leading design and manufacture.

This innovative approach is delivered through scalable architecture enabling numerous client applications to be supported with minimal tailoring and unique tooling. The architecture allows the motor & low-cost inverter to be integrated into client's hardware reducing parts count, weight and package dynamics.

Collaborative partners:

EMPEL Systems bring leading edge motor and power electronics design while accelerating their knowledge acquisition.

Shield Engineering (SMT) bring manufacturing know-how and resources.This project drastically advances Shield's plans to support clients with in-vehicle propulsion solutions.

Key to the useful outcome of this feasibility study is the contribution of strategic UK based suppliers of core commodities, components and manufacturing equipment. A range of such suppliers will be engaged from the outset to determine optimum specifications which will in turn protect the future scalable architecture requirements and frame the design for manufacture rules.

These suppliers will then be equipped to support EMPEL & Shields innovations and growth and the growing broader UK PEMD capability.

The project addresses the following investment areas:

Power Electronics Manufacture

Electrical Machine Manufacture

Electrical Steel and Magnet Materials & Manufacturing

It will be achieved through definition, value planning and DfM of scalable, core-technology e-motors and inverters for multi-voltage requirements and a large range of motor speeds torques. The products will be configured for stand alone, modular or integrated in-vehicle installation.

The project outcomes will include:

Higher-volume motor, inverter and key component designs with multi-voltage scalable architecture

Design for manufacture guidelines for core processes and components

Core process definition backed up by evaluation and verification trials, with estimated manufacturing process-flow, cycle-times and investment requirements at potential volume breaks

Production cost indications and challenges

Acceleration of automotive market opportunities.

Achievement of sufficient TRL and MRL enabling confident transition into future development and exploitation

The main focus areas include application of scalable architecture approach, disciplined DfM reviews with fully engaged UK strategic suppliers addressing the challenges and preconceptions of the industry and enabling investment in volume growth.