Conventional electrical machines suffer from the problem that due to their fixed windings, the number of pole pairs cannot be changed. Electrical machines are thus low-loss energy converters only for an optimized operating point. Apart from that point, the efficiencies of conventional electric drives are decreasing enormously.

The Intelligent Stator Cage Drive (ISCAD) system is an electric traction drive that uses aluminum bars in the stator instead of copper windings. Every bar is supplied by a dedicated power electronics unit. Compared to the fixed copper windings of conventional machines, the ISCAD system offers the possibility of varying the number of poles during operation. ISCAD creates the first electrical gearbox that can permanently adapt to the load profile and make better use of the battery capacity.

With the same size battery, the driving range can be increased by 25%. Optionally, an electric vehicle battery could be reduced by 25%, while maintaining the same driving range. In addition, because ISCAD operates at low voltage of 48V, costs for high-voltage safety measures and maintenance are eliminated. Another important reason for a 48V system is the intrinsic safety in the event of an accident, compared to the current high-voltage systems. The low-voltage ISCAD technology can be installed without risk, even by inexperienced people

For the production of ISCAD, no rare earths are needed. This offers cost advantages. By replacing the copper windings with aluminum bars, the production process of electronic motors is simplified.

The ISCAD system is not limited to the automotive market. Especially at sea, a low-voltage system is very desirable for safety reasons.

For more information, visit here .


Smart Lightweighting of Cars with 200kg

Tim Vorage, DSM, Heerlen, Limburg, The Netherlands

Weight reduction of cars enables an improved fuel economy. Shifting from steel to aluminum is the first step; the next step is introducing thermoplastic solutions. For Tii PA4T is an alternative to aluminum die-casting, and offers linear mechanical property profile from -35 to 150 °C. It is a semi-aromatic polyamide (PPA) and can be used in harsh conditions; for example, with road salt, coolants, and in direct contact with transmission oil at 150 °C.

For more information, visit here .

Automotive Stampings: Stronger than Titanium, Lighter than Aluminum to Make Vehicles More Than 100 Pounds Lighter

Gary Cola, Flash Bainite, Washington, MI USA

Globally patented Flash® Technology is a paradigm shift in steel research that employs counterintuitive grain expansion mechanisms that force intragranular chemically heterogeneous grain refinement leading to maximum-strength steel nanoscale microstructures. Requiring just seconds, minimal cost induction equipment heats readily available, low-grade steel to inordinately high temperatures, then water quenches using a proprietary thermal cycle.

For more information, visit here .

Streamliners Inc. Miniskirt: Aerodynamic Fuel Savings for All Types of Semi-Trailers

Richard Himmelmann, Streamliners Inc., Beloit, WI USA

The miniskirt improves the aerodynamic performance of any type of semitrailer by more efficiently directing airflow around the rear tires or tandems. The product saves 5-7% of the truck’s fuel use, saving thousands of dollars per year, per trailer. Its single-piece, semicircular design is lightweight and robust, and uses the four existing bolts on a dry van, reefer, or tanker trailer, and two clamps for an intermodal chassis or flatbed trailer.

For more information, visit here .

FuelBOX : Smart and Connected Fuel Quality Sensor

Alain Lunati, Jean François Mascaro, Audrey Guerin, Xavier Capron, Marielle Chauvel, Cédric Puerto, Géraldine Frankidjian, Thierry Gergaud, Nathalie Almakdessi, and Nicolas Richard, SP3H, Paca, France

These fuel quality sensors accurately identify the molecular content of fuels and automatically display information or necessary steps to the regulatory/legislative body through the vehicle’s existing connection. The generation and valuation of CO2 reduction, notably for regulatory reasons, affect both captive fleets and commercial vehicles; however, it could expand into all vehicles.

For more information, visit here .

See the rest of this year's winners: