Magnetics Business & Technology - May/June 2022 - 30

PRODUCT NEWS
Marelli Showcases 800V eMotor at CES in Las Vegas
280 Nm; a rear short motor with maximum power of 369 kw and
maximum torque of 540 Nm; and a rear long version with maximum
power of 340 kw and maximum torque of 328 Nm.
The stator uses hairpin winding technology with the flexibility to
vary the number of hairpins per slot and top-level slot hairpin
fitment capability in the range of 70-85%. The variable thickness
of the laminations improves the thermal heat transfer between
bar-to-bar and bar-to-iron.
In the rotor, high performance and efficiency is achieved by the
combined optimization in the choice of the magnets and rotor geometry.
Heat exchange design optimization is achieved through
the use of variable thickness laminations. Noise, vibration, and
magnetic cogging are all reduced by optimizing the skew of the
laminate stack.
The intricacies of hairpin windings and segmented magnets for
electric vehicle motors are not usual fare at the Consumer Electronics
Show in Las Vegas but this year they were on display
as Marelli showed its powerful 800-volt eMotor. The showcase
was part of the company's exhibition of its latest technology for
lighting, sensing, electronics, interior and electrification for the
automotive industry.
Visitors to the company's hospitality suite could view the motor,
even take a spin in a Porsche Taycan to feel first-hand the power
of 800-volt propulsion. Marelli's inverter technology for both cars
and motorcycles were also on display, along with its eAxle.
Marelli's 800V eMotor jacket, stator and rotor
Flexible dimensions and phase configuration include variable
stator active length, modular stator outer diameter, variable number
of hairpins per slot and variable rotor geometry. In its current
versions, Marelli uses specific segmented magnets to reduce
the effect of magnets losses. Each magnet can be segmented in
different sub-blocks to reduce the eddy current losses and each
sub-block must be electrically insulated by the other and by the
iron stack.
A top-tier supplier to the automotive industry, Marelli has been
developing e-motors more than ten years. Its product range
includes both 400-volt and 800-volt motors featuring 3-phase
permanent magnet synchronous technology, high torque density,
high-performance cooling system and speeds up to 25,000 rpm.
It was the first to market with 800V applications in 2020.
It has developed three basic configurations of the 800V: a front
version with maximum power of 175 kw and maximum torque of
30 Magnetics Business & Technology * May/June 2022
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Another design feature is Marelli's technique for reducing risks
due to shaft current. During normal operation, an eMotor shaft
may be at a different potential in respect to the eMotor chassis,
which is directly connected to the vehicle ground. This potential
may cause a current circulation through the bearings and this low
electric current can be potentially dangerous for the bearings.
Thanks to its experience gained from the current 800V electric
motor in production, Marelli says it is able to offer advanced solutions
to avoid critical risks related to magnets and bearings.
For more info, see www.marelli.com.
http://www.marelli.com http://www.MagneticsMag.com
Magnetics Business & Technology - May/June 2022

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