Magnetics Business & Technology - March/April 2020 - 34

s/^/KE^

hŶĚĞƌƚŚĞ,ŽŽĚŝŶWŽƌƐĐŚĞ͛Ɛ&ŝƌƐƚͲǀĞƌs͕ƚŚĞdĂLJĐĂŶ͗ZĞŵĂƌŬĂďůĞDŽƚŽƌĞƐŝŐŶĂŶĚ/ŶŶŽǀĂƟǀĞ
DĂŐŶĞƟĐdĞĐŚŶŽůŽŐLJ

Advancements in motor design and magnetic technology are central to the stunning high performance of Porsche's first-ever electric
vehicle, Taycan. Along with other design achievements in the highpowered auto, they likely point the way to future engineering trends
for the EV market.
The key element is a pair of exceptionally efficient permanently excited synchronous permanent-magnet motors with hairpin winding,
one on the front axle and one on the rear axle, thus making the cars
all-wheel drive. Both the range and the continuous power of the drive
benefit from the high efficiency of the motors which constitute an
electric machine that also functions as a generator for the batteries
during braking..

of hairpin technology is complex, but it allows the wires to be packed
more densely and thus increase the amount of copper in the stator.
While conventional winding processes have a copper filling factor of
around 45 percent, it is just under 70 percent in this case. This increases power output and torque for the same volume. Another important
advantage for a high-performance car like the Taycan is that a hairpin
stator can be cooled considerably more efficiently.

This electric machine, transmission and pulse-controlled inverter are
combined into a compact drive module. The rear axle module is installed parallel to the axle. The pulse-controlled inverter is mounted
on this in a balcony configuration to increase the luggage compartment volume. Thanks to its coaxial design, the front axle module is
integrated into the front of the vehicle in a very small space.
Permanently excited synchronous motors have a rotor with high-quality permanent magnets that generate a natural magnetic field. The rotor thus moves in sync with the magnetic rotating field of the stator,
which is why it is known as a permanently excited synchronous motor. A pulse-controlled inverter specifies the frequency of the rotating
field in the stator, therefore determining rotor speed. On account of
their structure, functionality and their excellent thermal behavior, the
permanently excited synchronous motors are able to deliver the high
performance that Porsche engineers were seeking.
A special feature of the Taycan's electric motors is the hairpin winding
in which the solenoid coils of the stator consist of rectangular rather
than round magnet wires. The wires are bent and their shape, before
they are inserted into the stator's laminated core, is reminiscent of that
of hairpins, hence the name for the type of winding. The open ends
are welded together using a laser beam. The manufacturing process

34

Magnetics Business & Technology * March/April 2020

The liquid-cooled synchronous motor on the front axle has an active
length of 160 mm and an active diameter of 190 mm. Its counterpart
on the rear axle is 210 mm long and has a diameter of 245 mm. All in
all, the modules have the highest power density of any electric powertrains on the market today, says Porsche.
Continued on page 33...

www.MagneticsMag.com


http://www.MagneticsMag.com

Magnetics Business & Technology - March/April 2020

Table of Contents for the Digital Edition of Magnetics Business & Technology - March/April 2020

Magnetics Business & Technology - March/April 2020
Contents
Editor’s Choice/ Features
Schaeffler Charges into EV Motors Business, Leveraging Acquisition of Elmotec Statomat & Close Ties with Automakers
Infinitum Motor Skips the Wound Coils in Favor of Printed Circuit Board Stator While Optimizing Magnetic Forces
Research & Development
HZDR Scientists Produce Engineered Magnetic Nanostructures in Dresden
Product News
Industry News
Events Calendar/ Advertising Index
Under the Hood in Porsche’s First-Ever EV, the Taycan: Remarkable Motor Design and Innovative Magnetic Technology
Visions
Magnetics Business & Technology - March/April 2020 - Magnetics Business & Technology - March/April 2020
Magnetics Business & Technology - March/April 2020 - Cover2
Magnetics Business & Technology - March/April 2020 - Contents
Magnetics Business & Technology - March/April 2020 - Editor’s Choice/ Features
Magnetics Business & Technology - March/April 2020 - 5
Magnetics Business & Technology - March/April 2020 - Schaeffler Charges into EV Motors Business, Leveraging Acquisition of Elmotec Statomat & Close Ties with Automakers
Magnetics Business & Technology - March/April 2020 - 7
Magnetics Business & Technology - March/April 2020 - Infinitum Motor Skips the Wound Coils in Favor of Printed Circuit Board Stator While Optimizing Magnetic Forces
Magnetics Business & Technology - March/April 2020 - 9
Magnetics Business & Technology - March/April 2020 - 10
Magnetics Business & Technology - March/April 2020 - 11
Magnetics Business & Technology - March/April 2020 - 12
Magnetics Business & Technology - March/April 2020 - 13
Magnetics Business & Technology - March/April 2020 - 14
Magnetics Business & Technology - March/April 2020 - 15
Magnetics Business & Technology - March/April 2020 - 16
Magnetics Business & Technology - March/April 2020 - 17
Magnetics Business & Technology - March/April 2020 - Research & Development
Magnetics Business & Technology - March/April 2020 - 19
Magnetics Business & Technology - March/April 2020 - 20
Magnetics Business & Technology - March/April 2020 - 21
Magnetics Business & Technology - March/April 2020 - HZDR Scientists Produce Engineered Magnetic Nanostructures in Dresden
Magnetics Business & Technology - March/April 2020 - 23
Magnetics Business & Technology - March/April 2020 - Product News
Magnetics Business & Technology - March/April 2020 - 25
Magnetics Business & Technology - March/April 2020 - 26
Magnetics Business & Technology - March/April 2020 - 27
Magnetics Business & Technology - March/April 2020 - Industry News
Magnetics Business & Technology - March/April 2020 - 29
Magnetics Business & Technology - March/April 2020 - 30
Magnetics Business & Technology - March/April 2020 - 31
Magnetics Business & Technology - March/April 2020 - Events Calendar/ Advertising Index
Magnetics Business & Technology - March/April 2020 - 33
Magnetics Business & Technology - March/April 2020 - Visions
Magnetics Business & Technology - March/April 2020 - Cover3
Magnetics Business & Technology - March/April 2020 - Cover4
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2021septemberoctober
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2021julyaugust
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2021mayjune
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2021marchapril
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2021januaryfebruary
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2020novemberdecember
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2020septemberoctober
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2020julyaugust
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2020mayjune
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2020marchapril
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2020januaryfebruary
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2019novemberdecember
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2019septemberoctober
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2019julyaug
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2019mayjune
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2019marchapril
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2019janfeb
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2018winter
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2018summer
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2018spring
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2017winter
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2017summer
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2017spring
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2016winter
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2016summer
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2016spring
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2015winter
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2015summer
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2015spring
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2014winter
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2014summer
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2014spring
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2013winter
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2013fall
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2013summer
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2013spring
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2012winter
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2012fall
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2012summer
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2012spring
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2011winter
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2011fall
https://www.nxtbook.com/nxtbooks/webcom/magnetics_2011summer
https://www.nxtbookmedia.com