Plastics News Europe - June 2018 - 9

automotive: vDi congress

rior PP trim panel by laser welding.
Although not yet optimised, water
assist cycle time was 95s (gas 120s).
The water assist part weighed 300g
less at 6 kg.
And in a Renault sustainability presentation, plastics strategy leader Sonia
Achard said Renault had used 56,000
tonnes of recycled PP plastics - mainly
post-consumer PP for 100% recycled
non-visible parts - worldwide in 2016,
a figure expected to rise to 67,000
tonnes/year by 2020. Renault has also
approved some new aesthetic appearance parts based on recycled industrial
PP and is working on extending recycling to LGF-PP. The auto maker is investigating the use of recyclate for closer tolerances parts, as well. Three
Renault plants implemented closedloop plastics recycling in 2017.
Achard also mentioned that PA6.10
and PA10.10 bio-sourced plastics were
under consideration for under-hood
applications. Moreover, some 20%
talc-filled PP is being replaced by 30%
natural fibre reinforced PP, such as Faurecia's Nafilean compound. While saving 6-20% in weight, these materials
typically cost some €2.50/kg more on,
e.g., the Megane car.

Electric motors
With electric mobility emerging as a
strong alternative to combustion en-

gines, it was no surprise that this was
an important topic at the congress this
year. Dr Thomas Walther, Arburg application technology manager, spoke
about the 2013-2016 ProLemo lightweight electric motor project. The project involved a rotor with a wound
carbon fibre composite or steel hollow
instead of a solid steel shaft, and replacement of a conventional high
magnetic permeability metal sheet
laminated stack with injection moulded rotor disc segments with recesses
to receive permanent magnets.
The outer part of each segment
was moulded in a soft magnetic composite (SMC). This is PA6 highly filled
with
permanently
magnetisable
Fe8Ni92 alloy (permalloy) particles,
with permanent magnets inserted
into recesses in the SMC moulding.
SMC reduces heat by lowering magnetic eddy currents more than with
laminated metal. It is 2-component
injection moulded with an inner GFPA6 component, changing mould inserts providing either a grooved
(splined) connection to a hollow steel,
or a low-stress hexagonal connection
to a hollow CFRP shaft.
Walther said Arburg used a
150-tonne clamping force Arburg
A520 moulding machine with a Polarform core-pulling rotating stack
mould, the 4min/segment cycle time

ProLemo lightweight electric motor parts displayed
at the IAA 2017 fair electromobility zone

meaning 360 segments/day, sufficient for 16,425 motors/year.
ProLemo aimed at overall rotor
weight reduction for lower moment of
inertia, enabling higher rotational
speeds for equal dynamics, but with
lower power consumption. Overall
weight of the ProLemo drive with a
hollow steel shaft and metal housing
was reduced by 21% or nine kilos
from 44.82kg to 35.56kg and 23%
with a hollow CFRP shaft to 34.31kg,
including a 11.09kg fibre reinforced
plastic housing. The weight reductions
correspond respectively to 12% and
16% moment of inertia improvement.
Other ProLemo partners included
Wittenstein Cyber Motor, WBK institute for production technology,

➡ Continued on page 10

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Table of Contents for the Digital Edition of Plastics News Europe - June 2018

Contents
Plastics News Europe - June 2018 - Cover1
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Plastics News Europe - June 2018 - Contents
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