Duratec

DRIVING INNOVATIVE
E-MOBILITY DEVELOPMENT

About the Customer

EVR Motors Ltd. is one of the new players in the e-mobility market. The company, based in Israel, designs and develops cost-effective radial flux Permanent Magnet (PM) electric machines for a range of power conversion applications such as renewable energies and vehicle electrification. EVR was established in 2012 and in the beginning developed patents for wind turbine generators. They adjusted their roadmap when public taste preferred e-mobility, and then developed a new electric motor called TS – RFPM (Trapezoidal Stator Radial Flux Motor) based on patented technology that provides increased power and torque density – all at lower cost of creation.

Their Challenge

For several decades, motors for electrical vehicles have been optimized using the same topology,
called Radial Flux Permanent Magnet Motor topology (RFPM). EVR chose to invent a new topology and develop a completely new type of motor for the electrical vehicle industry called the Trapezoid Stator RFPM topology, rather than try to optimize existing technology as other companies had been doing. 

As the base of EVR topology is different from other well-known motor topologies, the use
of multiphysics and optimization tools is highly important. This is why the team needed a reliable,
robust simulation tool.

Our Solution

When looking for a powerful and accurate electromagnetic and mechanical simulation tool, they
chose Altair® FluxMotor®, Altair® Flux®, Altair® SimLab®, and Altair® HyperMesh® – part of Altair’s complete solution for electric motor design – to simulate their motors prior to advancing to the prototyping phase. Because motor development involves many design iterations to meet all electromagnetic and NVH requirements, EVR chose the Altair solution, in particular the flexible, yet extremely capable, Flux software, to improve the virtual simulations to deliver results close to the physical prototypes.

Results

Today, EVR has already achieved a simulation accuracy of about 90%, but they’re aiming to
improve this to even higher accuracy of 95-96%. Since their electromagnetic design is brand
new and unique to existing technologies, this is a challenging task. But by using Altair’s solutions, EVR met this challenge and was able to reduce the number of prototypes needed, while meeting all project requirements and saving time to market. The new e-motor was not only lighter than all other motors on the market, it was also more cost-efficient, offering an innovative new smart solution to the extremely competitive e-mobility market.

Through simulation, EVR developed and tested its new patented motor, which is half the size
than some of the industry’s best e-motors. 

“Thanks to the Flux simulations, we lowered
the number of prototypes. Without the Altair solutions, we would not have been able to develop our new e-motor in such a short time,”

Opher Doron, Chief Executive Officer, EVR Motors.

TOP: 2D Magnetic flux isovalues in
the trapezoid Stator RFPM motor
BOTTOM: 2D Magnetic flux density in
the trapezoid Stator RFPM motor