n TECHNOLOGY A UK MANUFACTURER OF SUSTAINABLE, rare-earth-free electric motors, has unveiled a second generation of its motor technology, with stronger performance and higher e ciency. The HDRM300C motor incorporates Advanced Electric Machines’“revolutionary” compressed coil technology which achieves industry-leading conductor slot ll rates of more than 80%, compared to conventional layouts that typically achieve ll rates of less than 60%. The new magnet-free motor, aimed at heavy-duty and commercial vehicle applications, is said to represent a major advance in electric motor design. It builds on the success of AEM’s earlier HDRM150 motor, for which the company developed and validated its coil compression technology. The scaled-up machine delivers higher power densities and e ciencies. AEM says that the launch represents a signicant milestone in its mission to revolutionise motor technology and establish new standards for sustainable transportation. The new motor delivers 295kW of peak power (98kW continuous) at 700V DC, 700A rms. It can produce 485Nm of peak torque (180Nm continuous). The modular motors can be stacked to achieve higher performance. “The HDRM300C represents more than just an incremental improvement in motor technology,” says AEM CEO, James Widmer. “By combining our patented coil compression technology with enhanced thermal management and improved speed capabilities, we're delivering a motor that sets new benchmarks for e ciency and performance. For the transportation industry, this means more capable electric vehicles that are more coste¢ective to operate and maintain.” The motor’s increased speed capability provides greater £exibility for system integration in a variety of applications. Internal components, including bearings and busbar connections, have been strengthened to support the higher speeds. An improved cooling system, which works in a similar way to a car radiator, allows the machine to work harder for longer without overheating. This is particularly important for commercial vehicle applications, where consistent performance throughout the day is crucial. It will allow vehicles to carry heavier loads, climb steeper hills, and operate in more demanding conditions. Plug-in connectors have replaced traditional gland ttings, simplifying installation and maintenance, while enhancing reliability. The motors exhibit no cogging or electromagnetic drag losses at high speeds, resulting in high drive cycle e ciencies. Samples of the new motor are being trialled with selected partners, with full production due to start in Q4 2025. Advanced Electric Machines was founded in 2017, when it was spun out from Newcastle University’s electric motor research team, led by Widmer and CTO, Dr Andy Steven. Its motor designs and manufacturing processes are protected by 46 international patents. In 2023, the company attracted £23m of funding. The company’s vision is to design and build the world’s most sustainable EV motors for the global automotive and transport sectors. https://advancedelectricmachines.com Magnet-free UK motor delivers higher power densities and efficiencies ROCKWELL AUTOMATION HAS developed a software tool that allows manufacturers to conduct factory acceptance testing to validate automation systems before they are deployed. The Emulate3D Factory Test software provides factory-scale virtual testing of industrial controls using enterprise-scale digital twins that provide high-delity simulation and real-time collaboration. Rockwell says that traditional simulation tools often struggle to model complex factory environments, with thousands of moving parts, high-speed machinery and intricate system interactions. The new software is designed to overcome these challenges using a modular modelling approach that allows teams to build, verify and combine mechanical, electrical, control, robotics and device behaviour models into unied digital twins. “Manufacturers need scalable, high- delity digital twins to optimise system performance and accelerate commissioning times,” explains Matheus Bulho, Rockwell’s senior vice-president for software and control. “With the launch of Emulate3D Factory Test, we’re providing a solution that allows engineering teams to test, iterate and validate automation systems at full factory scale – leveraging the power of Nvidia Omniverse to deliver unprecedented visualisation and collaboration capabilities.” At launch, the new tool will o¢er: n multi-model orchestration, synchronising multiple system models for factory-scale testing; n modern DevOps work ows, designed to streamline version control, testing and deployment, allowing teams to work from the latest version, track changes in real time and maintain alignment; n a test runner function that enables repeatable, automated testing at scale; n a fault framework that simulates fault conditions to assess system resilience; and n advanced, full-factory visualisation, powered by Nvidia Omniverse APIs, that will be available initially via private preview. www.rockwellautomation.com Digital twins validate automation systems before they are deployed April 2025 www.drivesncontrols.com 18 AEM’s magnet-free motors oer high eciencies for heavy-duty applications
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