With EVs being all the rage in these times, electric motors are the heart of it all. There is a constant effort to make these motors lighter and fill them into a smaller form factor to extract the most range and power from EVs across all sectors.
EVR Motors just set up their motor winding plant in Manesar Haryana, where we got to witness how their patented trapezoidal geometry coils are being manufactured for domestic and global markets. Sajal Kishore, Managing Director, EVR Motors, gave us an in-depth look into their innovative approach and the future of EV motors.
PMSM & Radial Flux Topology
'Permanent Magnet Synchronous Motors (PMSM) are widely recognised in the automotive industry for their efficiency and performance,' says Kishore. 'What sets our technology apart is the radial flux topology, which is already a standard in the EV sector. We've enhanced this by altering the shape of the copper coil and the core of the motor, creating what we call the Trapezoidal Stator Radial Flux Permanent Magnet (RFPM).'
Elaborating on the technicalities, he says, 'The copper coil is the most complex component, and increasing the copper fill factor significantly impacts the motor's performance. While traditional motors have a fill factor of around 40%, our motors boast a fill factor of over 50%. This means EVR tech can deliver the same power and torque in a smaller package with lighter weight.'
Flexibility & Adaptability
One of the standout features of EVR Motors' technology is its adaptability. 'Our motors can be pre-tuned to operate at voltages ranging from 48 to 400 volts by simply changing the coil configuration,' explains Kishore. 'This flexibility is a significant advantage for OEMs, allowing them to optimise their power grids and incorporate more electronics and systems without redesigning the entire motor setup.'
This adaptability is particularly beneficial for vehicle OEMs facing evolving voltage requirements. 'If a customer needs to switch from 60 volts to 96 volts, we can adjust the number of coil turns without changing the motor's core design,' Kishore adds. 'This capability enables a seamless transition and reduces the overall cost and complexity for manufacturers.'
Licensing & Manufacturing Partnerships
EVR Motors operates on a strategic licensing model, collaborating with multiple partners to manufacture its motors. 'We've licensed our technology to various partners like RSV Transmissions for light commercial vehicles and Eco Mobility for electric buses,' says Kishore. These partners manufacture the motors using our designs, while we supply the coils from our facility in India.'
This approach has several advantages. 'By centralising the coil production we reduce the investment cost for our partners and enhance productivity,' Kishore notes. 'Coil winding typically accounts for about 40% of the cost in motor manufacturing, and our specialised machine, which has been developed after significant effort and innovation, optimises this process.'
EVR Motors prides itself on its innovative prowess. 'Israel, where EVR is headquartered, is known for its focus on technology and R&D rather than mass manufacturing,' Kishore explains. 'We excel at developing new technologies and enhancing existing ones, which is why we prefer to license our technology to partners who are experts in large-scale manufacturing.'
This strategy allows EVR to continue innovating while ensuring high-quality manufacturing through their partners. 'Our goal is to keep improving our motors, adding more value, and reducing costs while supporting our partners in delivering top-notch products,' Kishore says.
Global Reach
EVR Motors is not just focused on the Indian market but has a global vision. 'We have supplied working prototypes to customers in seven countries, including Japan, the US, and several parts of Europe and Southeast Asia. India, with its rapid adoption of EV technology and adaptable market, serves as an excellent base for our manufacturing operations,' Kishore reveals.
Looking ahead, EVR Motors has ambitious plans. 'Our current facility in India has the capacity to produce coils for about 20,000 motors per month, which can be expanded to 200,000 in the future,' Kishore states. 'We are open to setting up additional facilities based on customer demand and strategic partnerships.'
Kishore emphasises the importance of trust and adaptability in their partnerships. 'India and Israel share strong values of trust and innovation, making this partnership highly effective. The Indian market's rapid adoption of new technology and the increasing buzz around EVs make it the perfect environment for our innovative motors.'
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