Whatever your electric drive requirements, the Integral e-Drive division has been designed to offer you the best match to your needs.
The Revolution in Motion
Current Platforms Derivatives
We currently have a range of interior permanent magnet (IPM) and surface-mounted permanent magnet (SPM) platforms and can provide a solution rapidly, with minimum non-recurring engineering (NRE) if your requirements can be met by one of these. Using a simple application template to understand your system performance and constraints we can adjust length, windings and other aspects of our core technology package to give you the best performing motor.
Core Technology, Bespoke Motor (CTB)
A true differentiator of our business is the capability to configure our core e-Drive technology to meet your precise performance and package requirements. Once we have completed a simple application template we can use our in-house tools to outline a range of possible solutions and, working together with you, select the best match. Using an advanced, rule based design system Integral e-Drive can then rapidly design and procure optimised motors which automatically draw upon our proven expertise and experience.
Whilst the vast majority of applications can be met with our core technology bespoke (CTB) motors, there are applications so specific in their requirements or integration concepts that they need new core technologies for some of the sub-systems. This could for example be a motor designed to operate at the bottom of the sea or in a nuclear reactor cooled by liquid sodium. As genuine, first-principles engineers with a track record of meeting the most demanding briefs, Integral e-Drive are very well placed to meet your needs, however extreme.
Control Electronics and Software
Complementing our world class in-house inverter technology, Integral e-Drive also have a track record of working with other inverter providers according to technical and commercial requirements.
Our base software is Autosar compliant and has been developed in line with rigorous automotive standards running either on micro controller NXP SPC5744P, or where higher processing speed is required, a combination of this and FPGA from Xilinx.
Our application software contains all that is needed to drive SPM and IPM machines with precision and efficiency including speed and torque controllers, thermal models and system diagnostics. By using a model-based approach and established MiL / SiL / HiL validation processes we can also configure to meet specialist requirements when applicable.
Core Technology R&D
In 10 years of e-Drive innovation we have achieved genuine technology leadership in high power density motors and also cost economic low voltage drives; as a company led by engineers, we are passionate about maintaining this position.
We have a substantial on-going R&D program to evaluate new technology and to provide year-on-year improvements. All R&D activities at Integral e-Drive are managed through a series of gateways so that the most promising continue on a path that will allow them to be incorporated into our core technology and future products.
Current work-streams include:
- Advanced bearing systems
- Increased magnet retention system capacity
- A new winding concept for AC loss reduction and increased partial discharge resistance
- Use of advanced materials to improve cooling
- AC to AC inverter architectures
Examples of Products
Mid speed SPM
This 2nd generation series of mid speed SPM motors includes our first ever full life-cycle electric motor. Over 500 units of the launch version, a clean sheet design with 130kW at 18000 rev/min and 130Nm, were produced between 2011 and 2014 for a premium hybrid supercar.
With a mass of around 25kg this would still be a class-leading automotive machine but upgrading it with new core technology has resulted in the same frame producing 250kW at 29,000 rev/min and 200Nm. Derivatives of this machine continue to be made for a number of racing, special vehicle and test facility applications.
Ultra-High Speed SPM
The 3rd generation high speed SPM motors from Integral e-Drive were initially produced for combining with Turbo machinery. It has a mass of 3.7kg, a maximum rotational speed of 130,000 rev/min and a power density of 30kW/kg.
Low voltage IPM
The 4th generation IPM motor was designed to combine high performance with low (12-100V) system voltage and is fully compatible with high-volume manufacturing processes. Its integrated inverter weighs just 0.3kg and can provide 1000Arms phase current.
Heavy Duty IPM
Our 4th generation IPM motors use similar motor technology to our low voltage IPM motors but in a larger frame size. It is currently in use as a traction motor in a variety of heavy duty vehicles requiring power to be delivered over a very large speed range whilst matched to a low-cost inverter.
High Torque SPM
A 4th generation SPM motor which has a mass of 17kg, a maximum speed of 19,000 rev/min and a maximum torque of 300Nm. It illustrates well our scaled core technology strategy as this machine uses mostly the same sub-system technology already proven in our ultra-high speed SPM motors. It is currently being used for racing and automotive hybrid production vehicles and some experimental work in aerospace propulsion.
Calling on 20 years of experience in powertrain and controls engineering, we can support you with a tailored package that will ensure optimal performance in situ, however challenging your requirements.
Usually the motor will form part of a larger system and the application process starts with careful identification of requirements and interfaces which are captured in a sub-system specification document.
Design and analysis activities are guided by this specification and we will typically also design a customised application and validation program to ensure the motor is performing to specification before it is released for use.
We have a wide range of dynamometers, rigs and instruments to support these validation activities including:
- Performance and efficiency envelope
- Inverter mapping
- Thermal limits
- Insulation performance
- Speed, temperature and pressure cycling, sealing, vibration resistance
Full System Level
With nearly 20 years of powertrain engineering track record, we believe our ability to engineer motors into demanding applications is second to none.
We have successfully integrated machines into propulsion systems of many types, configurations and uses, into high-speed turbomachinery and into industrial equipment and test facilities. We have also dealt with harsh environments and duty cycles.
Where required, much of the application work can be carried out virtually using analytical tools and comprehensive plant models with SiL and/or HiL.
Once hardware is in place we can provide a comprehensive application and validation service for the full system or the Integral e-Drive team can work as support to your team to make sure the desired outcomes are achieved.
Whether you need a small batch or a million units, Integral e-Drive has the expertise to provide a quality assured, dependable manufacturing solution, in-house or in a dedicated facility.
For production volumes of up to 15,000 units per year, in-house manufacturing by Integral e-Drive may be the best option. We control our processes and supply base so that the product is matured early in the development cycle and we have an exceptional quality track record in production.
For higher volumes and also for lower volumes according to client needs, the best solution may be for manufacturing to be transferred to a different facility. In these cases, Integral e-Drive work with clients to ensure required IPR arrangements are in place and that there is a mechanism for any required support with manufacturing facility planning, supply base, Design For Manufacture (DFM) and Advanced Quality Planning (AQP).
As a director owned independent company, we can work flexibly to get an effective solution; whatever the chosen route our own future performance is secured by achieving the highest quality levels and commercial benefits for our clients.