Lund: New method of manufacturing magnetic components

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Researchers at Lund University in Sweden have developed a new way of making the magnetic components in electric motors that they claim will cut the cost of manufacturing motors in half, whilst doubling their output.

The technique is the result of fifteen years of collaboration between researchers from the fields of electrical power systems and industrial production at the Faculty of Engineering.

A key component in all of electric motors is the magnetically conductive material, usually made up of bundled laminated thin plates with coils wound around them. This involves many small parts and takes a long time to manufacture.

“Electric motors have largely been made in the same way since the 1850s. Only in the last 10-15 years have alternative production methods been studied,” says Mats Alküla, professor of electrical power systems.

Together with his research colleagues Tord Cedell and Mats Andersson, Alküla has found an alloy of iron powder and a certain (unspecified) type of plastic that functions well in motors, attaining good energy efficiency. By moulding together melted plastic and iron particles, parts can be made in various shapes that are weakly magnetic.

The number of production steps is reduced from about 60 to only a few.  The development of the material started in the late 1980s, funded partly by what is now Vinnova (Research and Innovation for Sustainable Growth).

“The technique is not suitable for high-performance motors, such as servo motors. But for fans, pumps, household appliances, and cars it’s perfect,” says Alküla.

This research is funded with a total of SEK 12 million over five years from Vinnova, the Foundation for Strategic Research (SSF), and Industri Kapital. A patent is pending, to be issued in late October. The researchers are now considering how to commercialise the technology.

“The technology could pave the way for new possibilities, such as facilitating the conversion of cars to electric hybrid power,” says Alküla.

A prototype of the technology will be on display this week at the Lund University Faculty of Engineering booth at the Technology Fair in Älvsjö, Stockholm, Sweden.