India Nippon Electricals has developed a generator system comprising an AC generator and electronic controller which yields efficiency of 85%. The joint venture company of Lucas Indian Service and Mahle Electric Drives Japan Corporation makes electronic ignition systems for two/three-three wheelers and general purpose engines.
R Umashankar, CTO, India Nippon Electricals, told Mobility Outlook that a generator is generally designed to provide maximum efficiency at a particular operating point. However, when this changes because of a change in load or speed, the efficiency of the system drops.
In the new system, the controller is designed to work at the maximum efficiency point of the generator irrespective of load or speed. “We can achieve over 85% efficiency as compared to 60% in a conventional system,” explained Umashankar.
“Today, many applications like high-end motorcycles, snowmobiles, ATVs etc use rare-earth (neodymium) magnets for generating electric power. Availability of these magnets is controlled by one country,” he continued.
Hence, the company set about its task to use a standard ferrite magnet and obtain high output on a par with rare earth magnet design. By improving efficiency, it achieved its goal.
According to Umashankar, use of rare earth magnets under high temperature is a different ballgame compared to ferrite magnets. They get demagnetised at over 200 degree Celsius while ferrites can withstand up to 450 degree Celsius.
Thanks to higher efficiency levels, the stator of the generator is also cooler and with no need for forced oil cooling as in the conventional system. All in all, the ferrite magnet, cooler stator and better fuel economy translates into better cost savings.
New Opportunities
The company is working with customers in India, the US and Europe to launch this in on/off-road applications. It is also keen on expanding its portfolio of ferrite magnet-based generators into motors where the challenge lies in packaging. “We are confident that with advanced simulation tools, we will provide our customers a cost-effective product,” said Umashankar.
India Nippon Electricals has developed motor controllers, DC-DC converters and chargers for electric two-wheelers. The focus is on sub 6kW motors and controllers for EVs. It is also working with 2W OEMs in connected vehicle technologies.
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