WMG, at the University of Warwick, is playing a key role in the UK-ALUMOTOR consortium working to build on the UK’s electric motor supply chain by leveraging manufacturing expertise to deliver the next generation of sustainable electric motors.

The consortium, led by Ricardo, will deliver a tested and validated pre-production, highly sustainable motor, with up to 12kg reduction in rare earth magnets per machine. This will enable the UK to scale motor production and accelerate the transition to electrified transport, as well as build and secure its national capability and domestic supply chain without risk from international markets, so providing competitive advantage.

The consortium is also investigating higher performance derivatives, suitable for passenger cars, defence and motorsport applications.

WMG’s role as the project’s stator integration lead is to use the DER Winding Centre of Excellence to help build several novel synchronous reluctance e-machine prototypes, helping to develop a range of manufacturing processes to pre-production level for the pre-production design. Engineers and researchers at WMG will conduct process development and components testing, leveraging work on earlier APC funded projects, to advise the partners on design for manufacture, bill of processes, and end of line testing to provide a viable manufacture solution.

Funding for the project has been awarded by UKRI’s Driving the Electric Revolution and will allow the consortium to take the light commercial vehicle motor concept to a much higher level of manufacturing readiness.

This two-year project builds on previous successful collaboration between the consortium in 2021 as the UKRI funded feasibility study was delivered. WMG has supported the design since its inception through earlier DCR project with Ricardo in 2020.

Teri Hawksworth, President of Ricardo Automotive and Industrial EMEA, said: “The cost of electrification is widely recognised as being the biggest barrier to wide-scale adoption of electric commercial vehicles. Manufacturers are also concerned about the supply security and volatile costs of the rare earth metals used in most zero emission vehicles. Ricardo is committed to supporting manufacturers by driving cost out of electrification, leveraging our world-renowned expertise in motor innovation, and driving sustainable technology solutions which will support the UK in achieving its net zero carbon emission targets for commercial vehicles by 2030.”

David Simkin, Head of the DER Winding Centre of Excellence (WCE), said: “The challenge of taking a novel topology of eMachine to early stage production is exactly what the DER WCE facility was designed to deliver. Taking the experience and knowledge gained in the earlier UK-ALUMOTOR program to early phase manufacturing will build on the manufacturing process and training skills already at WMG. Manufacturing of eMachines in the UK is necessary to move to a zero emissions outcome in the UK. It is the priority of the WCE to support UK manufacturers and UK supply chain companies to satisfy this market opportunity in electrification, and this project provides a perfect opportunity for us to do this.”

In addition to consortium leader, Ricardo, the project consortium partners include: Aspire Engineering, Brandauer, WMG, Phoenix Scientific Industries, and Global Technologies Racing.

Find out more about WMG’s Transport Electrification research here.