Technology viability

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Technology viability

These all point to the application in a in-wheel motor. It just makes sense. Multiple functions in a single solution The innovations behind the Elaphe electromagnetic topology fully utilize a big majority of electromagnetically active parts. Parts are designed to fulfill multiple functions, such as the magnetic flux or the electrical current bearing, the heat removal and structural rigidity at the same time.

This is the path to a light-weight, low-cost and simple production Production Elaphe uses state-of-the-art manufacturing technologies to produce in-wheel motor elements.

Technology viability

It begins with the design stage where every part is 3D printed, assembled and tested for achieving assembly restrictions. Every in-wheel motor component is designed for mass manufacturing in order to reach commercial viability and enhance simplicity without compromising the reliability of the product.

Aluminium casting technologies, CNC milling and turning, grinding, laser welding and cutting, water jet cutting and stamping. Choice of technology stems from design demands, specified tolerances and approximate production volumes.

Using the vast experience in motor design and assembly, Elaphe is dedicated to develop own assembly and production tools in order to make production process more efficient and scalable. Even at the prototype stage the production follows standards which are applicable in mass production of in-wheel motors.

Elaphe uses semi-automated and automated tools to assemble the motors in optimal tact times. Every stage of the assembly process includes several quality control checks, to ensure maximal quality and standards compliance of the assembled products. Quality control Every component of the Elaphe in-wheel electric motor is tested for faults and defects.

Technology viability

Each element is tested for geometrical compliance using machine vision and on the 3D coordinate measuring machine in order to ensure manufacturing repeatability. Elaphe ensures that all in-wheel motor materials are tested according to automotive standards.

Condition monitoring In-wheel motors are exposed to variable loads, which result in mechanical, thermal and electrical stress to the motor. Testing is done in a laboratory and on the operating vehicles.

Technology readiness level - Wikipedia

By monitoring critical mechanical and electromagnetic parameters of the in-wheel motor, we can detect and even predict faults, thus maximizing the service life and safety of our direct drive motors.

We strongly believe that condition monitoring is essential to the acceptance and the future development of the automotive in-wheel motors.

Testing Elaphe Propulsion Technologies Ltd. Given the fact that our existing in-wheel motors produce up to kW and that we require the ability to test the motors in continuous conditions, we have developed a special concept of a measurement station. The flexible power source concept can provide a DC source from V, either from the grid or from our battery bank — but the power that is used for running the motor is largely returned to the system by the identical motor used as an electrical brake.

The cooling system is very similar to those used in regular cars and is equipped with valves and sensors of flow and temperature so different cooling conditions can be simulated.

Design Tech for IB students

The test bench is controlled by our own automatic measuring program, that calibrates itself to the tested motor and carries out the desired testing procedures. Automatic data processing ensures that measurements are comparable and can be tracked over a long period of time.

Since the motors are controlled directly from the testing software, driving cycles can be imposed and continuous tests can be performed for real conditions. Besides lab tests, Elaphe also tests in-wheel motors on development vehicles in the real environment.

The vehicles are used in a variety of different driving conditions, such as snow, mud, rain, gravel and sand. The vehicles are also used on a daily basis by the Elaphe personnel and have been an exceptional reliable source of clean and efficient transportation for many years now.

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Technology – Elaphe in-wheel electric motors