In this exclusive ESI Africa article with Future Market Insights, we consider the Middle East and North Africa (MEA) as potential market regions for electric vehicle drive motors.

The concept of electric vehicles (EVs) is not something new to the world. However, with technological advancements and a growing concern over pollution, it has been given the status of the vehicle of the future.

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EVs are powered by electric motors which replace internal combustion engines. In addition to batteries, electric motors are the core components of an EV. Various types of electric motors can now be used in electric vehicles thanks to rapid advances in the field of power electronics and control techniques. For automotive applications, electric motors should have characteristics such as high starting torque, high power density and high efficiency.

In a report recently published by Future Market Insights, battery & hybrid electric vehicles are demonstrating better fuel efficiency over time, as a result of which there is a shift towards electric vehicles, which is increasing the demand for electric vehicle drive motors. The demand for electric vehicle drive motors is also increasing with the increased use of EVs, especially in countries in the Middle East and Africa. In these countries, the goal is efficient energy conservation and low carbon emissions, which is why they are opting for electric vehicles. Electric motors are the heart of an EV – they need to be manufactured efficiently.

Innovative electric motor technologies are being adopted by various manufacturers across the MEA. This can result in lower manufacturing costs and, ultimately, a lower selling price for the EV, making it affordable to a variety of classes across society.

This blog will highlight the use of brushless DC Motors that offer enhanced flexibility of drive, how manufacturers are testing the efficiency of E-motors with universal inverters, and new developments, like the magnet-free electric motor in Dubai, which is a revolutionary innovation for the EV motor market.

Early electric vehicles were limited to speeds of 20 miles per hour due to the lack of electronic control technology. With the convenience of gasoline-powered cars and poor recharging infrastructure, car owners abandoned electric vehicles. These energy-efficient automobiles, however, have become more feasible thanks to technological advancements like brushless DC motors (BLDC motors).

BLDC motors are used in all hybrid vehicles today and are often preferred by green car manufacturers, as they offer higher peak point efficiencies and simplified rotor cooling. Motors can also operate at a “unity power factor,” which means the drive can operate at its maximum efficiency level. Batteries are an extremely crucial part of the BLDC motor drive system. They also provide energy to the engine and allow the electrical receivers to work. Thus, green cars must have the highest efficiency possible when it comes to batteries.

Due to their fast motor response, companies like NASA and green car manufacturers prefer BLDC motors. Due to the small diameter of high-performance magnetic rotors, the armature can accelerate more quickly and rotational losses are reduced, resulting in smoother servo characteristics. As a result of this optimal motor response, instant speed regulation, more constant speeds, and a quieter drive system are possible.

For instance, FAULHABER, an e-motor manufacturer and distributor in Qatar, brushless flat DC-micromotors are 3-phase, slotless motors with axial flux gaps and rotating back irons. They are much more efficient than other brushless motors and have a rotating back iron. This provides high rotor inertia that is ideal for applications requiring low torque ripple and extremely accurate continuous speed control.

Besides brushless motors, FAULHABER also offers motors with cylindrical rotating back irons, sometimes known as ironless external outrunner motors. The slotless design of the FAULHABER motor eliminates the torque associated with cogging. These motors are suitable for continuous duty applications requiring very precise speed control due to the high inertia of their rotor. They can also be configured for different speed profiles with the integrated speed control.

The scientists will be able to adjust the strength of the magnetic field so that the magnetic field will be at maximum strength when an electric vehicle requires maximum torque, particularly at low speeds. The brushless DC motor is expected to dominate the market as green vehicles gain in popularity.

Have you read? Latest global electric vehicle outlook appears confident, but cautious

E-mobility is characterised by rapid technological change. All variables, such as battery voltages, motor speeds and motor types, are subject to change. If a manufacturer wants to develop products for this market, they will need a motor testing solution that can enhance the motor efficiency of the EV.

As an example, consider the e-Motor testing case. Several manufacturers, especially in Africa, are offering solutions that combine a Battery Emulator, an AC Dyno and a Universal Inverter, all in a single package. These solutions are powered by a single active front end. Combining these features reduces wiring complexity, simplifies installation and saves energy.

Unico’s Universal Inverter, for example, can convert all of the most common AC motor types (Synchronous Permanent Magnet, Asynchronous Induction, and Internal Permanent Magnet) without having to change hardware or load different software.

Unico offers a variety of ratings, but its most popular model is a water-cooled inverter that can accept a DC input of 0-900VDC. The switching frequency can be adjusted up to 24kHz. There is a dynamic protection curve built into the inverter. This protection curve automatically adjusts based on operating conditions such as DC input voltage, switching frequency, overload, output frequency and ambient temperature.

An IPM motor’s flux maps can be generated by the Unico Universal Inverter, which includes automated test routines. The d-axis flux and the q-axis flux, as well as motoring and absorption, are each mapped separately. The flux map data alone can be invaluable for a motor designer. However, the Unico Universal Inverter can utilise these data to generate current vectors that are optimal for any combination of speed and torque.

Testing and developing next-generation e-motors with a Unico Universal inverter will not only offer engineers an expedited production process but technical guidance will also be provided to system integrators and EV manufacturers. This is to ensure the optimum configuration of the test stand to meet their current and future research and development requirements.

The electric motor must run at high efficiency to preserve and maximise battery life. The primary component of an electric motor is a magnet. However, recently a manufacturer in Dubai came up with a groundbreaking innovation for electric cars.

Mahle Group showcased its newest developments in e-mobility at Dubai World Expo. One of the group’s recent announcements is a revolutionary magnet-free electric motor. Mahle’s extensive know-how allows it to create integrated modular and system solutions for e-mobility applications as a leading international development partner and supplier to the automotive industry.

Mahle’s magnet-free motor represents a revolution in the development of electric motors since it brings together the strengths of various electric motor concepts that previously could not be combined. As an electric motor does not rely on rare earth elements, it is particularly sustainable and cost-effective. The only instance of it running at wear-free levels has been in Formula E race cars. Currently, the company plans to expand its use to other EVs and improve the efficiency of the motors inside these vehicles. The electric motors will cost less if they do not contain magnets and, therefore, the overall price of the EV can be lowered. From passenger cars to commercial trucks, it can be installed in a wide range of vehicles.

Mahle presents an intelligent fast charging system from its corporate start-up chargeBIG with outputs of as much as 750kW, as well as a new battery cooling system to prevent overheating, enabling fast charging in just a few minutes. This is meant to maintain the quality of the magnet-free electric motors and prevent any kind of internal circuit accident within the vehicle.

This group’s strength is its ability to integrate pedal-driven components without obtrusion into electric vehicles. These components include compact and lightweight rear wheel hub motors, electronic control units, batteries, and other pedelec components. As a complement to the hardware, an integrated connectivity solution featuring mobile and web-based apps is used to monitor the functioning and any problems that may be encountered by the EV motors.

Have you read? Demand for electric vehicle batteries expected to surge

Electric vehicles use a battery to supply electrical energy to the stator, which spins the rotor, which then provides mechanical energy to drive the car’s gears. As the gears turn, the wheels turn as well. It all happens in the blink of an eye, without burning fossil fuels! This is due to efficient electric motors in EVs.

Middle East countries are becoming more interested in electric vehicles because of their green features – low pollution and low carbon emissions. To make it more affordable to a broader segment of society, these countries have developed innovations to enhance the efficiency of these cars.

There are also partnerships in place to launch better and more efficient electric motors, such as in Africa. Jet Motors company recently announced its partnership with Nigeria’s GIG Logistics (GIGL) to develop the first electric cargo van in the country, the JET EV. Their ultimate goal is to create Africa’s Tesla.

Nigeria’s first locally made, fully electric road car, Jet EV, is now available with zero emissions on Nigerian roads. On a full charge motor, the Jet EV travels between 260 and 280km, but can technically cover 300km. These electric vehicles reduce maintenance costs by almost 70% by reducing the number of engine parts. Operating costs, including refuelling, dropped significantly as well.

The most attractive feature of this EV is its electric motor. It is a DC motor that increases battery efficiency and requires little energy to power the vehicle for more than 20 kilometres. It features a high-capacity lithium-ion phosphate battery rated at 107.6kwh, and a motor with 950Nm of torque, enabling it to accelerate from 0-100km/h in under 20 seconds. They plan to rapidly get the right funding and install charging stations across African cities and on African highways. This will make it easier for individuals and corporations to embrace the electric car since they are more likely to buy one if they know they can charge it. Additionally, a cost-effective form of inverter technology and magnetic-free motors is being considered for future vehicles. ESI

Find out more about the Future Market Insights report on the Electric Vehicle Drive Motor Market.

Sudip Saha, the ‘Mozart of Market Research’, a moniker given to him by his peers, is the COO of Future Market Insights an ESOMAR-certified market research and consulting company and a member of Greater New York Chamber of Commerce.

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