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05/17/24

SUSTAINABILITY REPORT 2023

Alvier provides the mobility industry with a wide range of engineering services to support sustainable electrified propulsion solutions across various markets, including automotive, commercial vehicle, off-highway, marine, aerospace, and industrial applications. Our sustainability focus centers on optimizing the reduction of CO2 emissions during the development process, resulting in an overall reduction. This commitment aligns with both our company’s and the customers’ efforts to reduce CO2 emissions during system operation.

Alvier Mechatronics started their sustainability journey in January 2023. Our company elected a sustainability champion who received expertise training on Sustainability. The sustainability champion then started research on the topic and exposed the rest of the company to sustainability. Some sort of sustainability topic is typically talked about in our design tasks, but never the term or all inclusively. This was a learning experience for all to discover the contributions we make already and uncover the gaps we have.

Our first area of focus is the United Nation’s Sustainable Development Goals, or SDG’s. This report shows our achievements so far in less than 1 year. In future reports, our plan is to create additional metrics in current focus areas as well as metrics in even more areas to support as many SDG’s as possible. Our hope is to expand the areas each year.

PUBLICATIONS

05/17/2024

Partnership driving forward sustainable electrification

The mobility industry is facing mounting pressure to achieve sustainability and efficiency goals while maintaining cost-effectiveness. 

Alvier Mechatronics, experts in advanced materials and production methods for sustainable high-volume applications in partnership with Drive System Design (DSD), specialists in rapid engineering, development and electrified propulsion systems, have unveiled their next generation integrated drive system (iDS). Since the partnership's launch in 2022, DSD's expertise in rapid development engineering and AlvierMechatronics' experience in novel manufacturing methods for sustainable high-volume applications, material know-how and electromagnetic design have focused upon the iDS. Through efficient collaboration, the design was brought from concept into validation in a time frame far shorter than the industry standard.

 

“The development of the iDS, encapsulating game-changing technology that delivers sustainable propulsion, is only the start of this strategic partnership with DSD” – Daniel Hervén, CEO AlvierMechatronics.


Over the coming weeks, we will demonstrate how we have brought new technologies to life more quickly than the industry standard using our development methods, while increasing efficiency and sustainability.

04/10/24

WILL YOU JOIN IN?

We are delighted to invite you to our Sustainability Day. You can look forward to interesting presentations on eDrive solutions for a more sustainable future.

 

When: 2024-05-21 / 12.30 – 17.00 PM

Where: Henckels Torg 3, Helsingborg, Sweden

 

Speakers:

// Volvo Trucks

// Lund University

// Höganäs

// Additive Drives

// Alvier Mechatronics

 

Since the places are limited, write us a short email if you would like to participate:

write us an email

03/07/2024

ADVANCEMENTS IN RADIAL FLUX ELECTRIC MACHINES: USING SMC TECHNOLOGY

Our customers often request the development of energy-efficient and eco-friendly electrical systems. Electric machines play a pivotal role in a wide array of applications, including electric vehicles, renewable energy systems, and industrial machinery. 
The adoption of SMC technology presents an exciting opportunity for cost-effective, high-efficiency electric machines, catering to the growing demand for sustainable and energy-efficient solutions.

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02/22/2024

REDUCE MACHINE COST WHILE STILL MEETING SPECIFIC PERFORMANCE REQUIREMENTS

One of the most common challenges our customers face is the need to reduce machine cost while still meeting specific performance requirements. Additionally, the design must respect various constraints like torque ripple reduction, mechanical robustness, and thermal loading.

MULTI-OBJECTIVE OPTIMIZATION
Our approach to efficiently solving these problems involves the application of multi-objective optimization, achieved by coupling integrating scripting tools (MATLAB and Python) and FEA tools (Ansys Motor-CAD and JMAG).
 
WE'RE NOT LIMITED TO JUST ONE TYPE OF MACHINE!
Our expertise extends to the design of a wide range of electric machines, including (but not limited to):

  • Wound Field Synchronous Machines
  • Induction Machines
  • Synchronous Reluctance Machines
  • Spoke Interior Permanent Magnet Machines
  • Multi-Layer V-Shape Interior Permanent Magnet Machines
  • Axial flux machines

With our wide range of knowledge in electric machine design, Alvier Mechatronics can provide you with an optimized solution with regards to requirements and constraints.

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02/15/2024

EXPLORING ELECTRIC MACHINE TYPES: MAKE INFORMED DECISIONS

At Alvier Mechatronics, we specialize in electric machine design and optimization, providing practical solutions to meet your unique needs.
 
Our customers often request the design and comparison of various electric machine types and consider the strengths and limitations of each type to make informed decisions for specific applications.  
 
Understanding the pros and cons of these electric machine types is crucial for making informed decisions in various applications. If you want to learn more, please contact Alvier mechatronics sales team. 

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01/04/2024

A good start into the NEW YEAR 2024!

We wish you a perfect start to a successful 2024. We look forward to exciting projects and an inspiring exchange, for example at the Advanced E-Motor Conference 5.-7. March 2024 in Munich.

We have achieved a lot in 2023 and have even more planned for 2024: Further development of our Axial and Radial Flux motor designs, focusing on sustainability by expanding our CO2 optimization services and enlarging our global footprint in China and the United States. To achieve all this, we will grow as a company and as a powerful multinational team.

 

 

12/17/2023

Enhancing Fidelity: The Step-by-Step Advancement of Electromagnetic Models through Additional Details

Introduction

Electromagnetic models play a pivotal role in understanding and harnessing the fundamental forces of nature. From designing efficient communication systems to developing cutting-edge medical devices, electromagnetic models serve as the foundation for a wide array of modern technologies. The accuracy and fidelity of these models are essential for successful applications. One proven approach to improve their accuracy is by adding more details, which enhances their fidelity incrementally. In this essay, we will explore how the step-by-step addition of details to electromagnetic models leads to increased fidelity.

Fundamental Concepts and Simplified Models

To comprehend the significance of adding details to electromagnetic models, it is crucial to begin with a basic understanding of fundamental concepts. Electromagnetism, as described by Maxwell's equations, governs the behavior of electric and magnetic fields. Simplified models often serve as the starting point for analysis. These models provide a high-level overview but lack the intricacies required for precise predictions.

Incorporating Material Properties

One of the initial steps in enhancing electromagnetic models is the inclusion of material properties. Real-world materials exhibit varying electrical and magnetic characteristics. To increase fidelity, models must consider parameters such as, permeability, and conductivity. Incorporating these properties allows for a more realistic representation of how electromagnetic fields interact with materials. One aspect that significantly affects model fidelity is the consideration of electromagnetic losses.

Electromagnetic losses in materials occur due to a variety of physical mechanisms, and they can have a substantial impact on the behavior of electromagnetic fields. To increase the fidelity of electromagnetic models, it is imperative to account for these losses in materials.

Materials with magnetic properties, like ferromagnetic or ferrimagnetic substances, experience losses through mechanisms such as hysteresis and eddy currents. Accurate modeling of magnetic losses is crucial for understanding energy losses, as well as predicting the behavior of inductors, transformers, and magnetic shielding materials.

Geometric Complexity

Electromagnetic systems often involve intricate geometries that cannot be adequately represented by simplistic models. Adding geometric details, such as tooth tips, slot radiuses, and insulation material, becomes necessary for accurate simulations. These details ensure that models reflect the physical world with precision.

Meshing and Discretization

To analyze electromagnetic phenomena in complex geometries, numerical methods like the finite element method (FEM) or finite difference time domain (FDTD) are commonly employed. These methods require discretization of space into smaller elements or grids. Fine-tuning the mesh or grid resolution allows for a more detailed analysis, as it captures localized effects and boundary interactions accurately.

Time-Dependent Behavior

Many electromagnetic phenomena exhibit time-dependent behavior, which necessitates modeling changes over time. Including temporal details such as time-varying sources, transient responses, and dynamic material properties further enhances the fidelity of electromagnetic models. Time-domain simulations provide insights into how systems evolve in real-world scenarios.

Frequency-Dependent Effects

Electromagnetic systems often operate at various frequencies. Modeling frequency-dependent effects, such as dispersion and resonances, requires additional details. Frequency-domain analysis, such as the use of complex permittivity and permeability, is crucial for accurately predicting how electromagnetic fields interact with materials and structures across different frequencies.

Coupling and Multiphysics Interactions

In many practical applications, electromagnetic systems interact with other physical phenomena, such as heat transfer, fluid dynamics, or structural mechanics. Including these multiphysics interactions in models increases their fidelity by considering the complex coupling between different physical domains.

Validation and Experimental Data

The final step in enhancing fidelity involves validation against experimental data. Comparing model predictions with real-world measurements is essential to confirm the accuracy of the model and identify any discrepancies. This iterative process may lead to further refinement of details in the model to align predictions with experimental results.

Conclusion

In conclusion, the step-by-step addition of details to electromagnetic models is a fundamental approach to increasing their fidelity. Beginning with fundamental concepts and simplifications, models evolve to incorporate material properties, geometric complexity, meshing, time-dependent behavior, frequency-dependent effects, multiphysics interactions, and validation against experimental data. Each of these steps enhances the model's accuracy, allowing for more precise predictions and applications across various fields, from telecommunications and medical devices to aerospace and beyond. As technology continues to advance, the continual refinement of electromagnetic models through the addition of details will remain essential in our pursuit of understanding and harnessing electromagnetic phenomena.

 

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12/10/2023

How Can Alvier Mechatronics Reduce the CO2 Footprint of an Electric Machine by 40%?

Sustainability remains a paramount concern for leading companies worldwide. Within the broader context of sustainability, mitigating carbon emissions holds a position of utmost importance. 

Reducing the CO2 footprint of the products a company produces has a major impact on the earth’s atmosphere and environment. Additionally, companies that reduce their carbon footprint support the United Nations 17 Sustainable Development Goals (SDG's) and the Paris Agreement (Link2) targets.

 

At Alvier Mechatronics, we actively champion these objectives by developing innovative and sustainable design solutions. Our primary focus areas for sustainable designs include:

  1. Increase Energy Efficiency: Ensuring optimal performance with minimal environmental impact.
  2. Reduce/Eliminate Toxic Materials: Minimizing or eliminating the use of toxic materials, prioritizing the health of both consumers and the planet.
  3. Improve Waste Prevention, Recycling, and Reuse: We emphasize the importance of responsible waste management, promoting practices that contribute to a circular economy.
  4. Create value for customers: Starting with the customers’ needs, add value in as many aspects as possible.

In a recent comprehensive CO2 reduction study, we engineered a traction motor equivalent that achieved a 40% reduction in the electric motor's kg CO2e. This achievement was realized through detailed analysis of the supply chain, involving Tier 1 suppliers from Germany and Tier 2 suppliers from the Czech Republic. Furthermore, our study identified the potential for even greater reductions by incorporating Tier 1 suppliers from the USA and Tier 2 suppliers from Canada or other countries with lower kg CO2e/kWh values. (Five supply chain variants were evaluated in the study.)

 

Key factors influencing the reduction in CO2 emissions from our study include:

  1. Advantageous Use of SMC Stator: Opting for a Soft Magnetic Composite (SMC) stator, as opposed to traditional electrical steel sheets (laminations), emerged as a pivotal decision.
  2. Magnet Types, Grades, and Quantity: Variances in the types, grades, and quantity of magnets used in the motor significantly influenced CO2 reduction.
  3. Weight Reduction: Lower weight emerged as a crucial factor contributing to the overall reduction in CO2 emissions.
  4. Supply Chain Influence: Choosing the right Tier 2 supplier, particularly focusing on raw material sourcing, played a pivotal role in achieving our CO2 reduction goals.

If you wish to delve deeper into any of these concepts or explore how Alvier Mechatronics can assist in realizing your sustainability goals, please don't hesitate to contact our experts. We offer a range of services dedicated to supporting your company's vision for a more sustainable future

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Radial flux machines, which have a more traditional cylindrical shape, are widely used in electric vehicles. ©Alvier Mechatronics

12/03/2023

How axial flux can transform your BEV drivetrain!

Axial flux and radial flux are two different electric machine designs that can be used in a battery electric drivetrain, and each has its own set of advantages and considerations.

Axial flux machines, also known as pancake machines, have a unique design where the magnetic flux flows parallel to the axis of the machine. This design allows for a more compact and lightweight solution compared to traditional radial flux designs. The flat, pancake-like shape of axial flux machine enables them to be integrated more seamlessly into the drivetrain, making them well-suited for applications where space and weight are critical factors.

One key advantage of using axial flux motors is their high power density. The compact design allows for a higher power-to-weight ratio, which can result in improved acceleration and overall performance of the electric vehicle. 

 

On the flip side, there are some challenges associated with axial flux machines. The manufacturing process can be more complex and may require specialized techniques. This can potentially impact production costs, although advancements in manufacturing technologies are continually addressing these challenges.

In contrast, radial flux machines, which have a more traditional cylindrical shape, are widely used in electric vehicles. They are known for their simplicity and reliability. However, they may not achieve the same power density as axial flux machines, and the overall size and weight of the machine can limit design flexibility.

Choosing between axial and radial flux machines depends on the specific requirements of the electric drivetrain and the intended application of the vehicle. If maximizing power density and minimizing weight are top priorities, axial flux machines could be the preferred choice. On the other hand, if simplicity, reliability, and cost-effectiveness are critical considerations, a radial flux machine might be the more suitable option.

One key advantage of using axial flux motors is their high power density. ©Alvier Mechatronics

 

Ultimately, the choice between axial and radial flux machines involves a trade-off between various factors, and it highlights the importance of considering the specific needs and goals of the electric drivetrain in question. A good way to perform such an analysis is with a systems optimization toolbox, such as ePOP.

If you’d like to discuss the trade-offs between axial flux and radial flux further, please contact Gerald Römpp, and we’ll set up a meeting with our technical experts to discuss how your problem could be analyzed faster, and with higher quality.

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Automated simulations enable engineers to quickly evaluate different scenarios, such as the impact of altering core materials, coil designs.

11/26/2023

How Alvier Mechatronics cuts development time of electric drive modules by 50%?

Automated simulation workflows are invaluable in the field of electromagnetic energy conversion, where precision and efficiency are paramount. These workflows offer numerous advantages tailored to this specific domain.

Efficiency is a key advantage. Electromagnetic energy conversion systems involve complex interactions between magnetic fields, electrical circuits, and mechanical components. Automating simulations in this context accelerates the design and optimization process. It enables rapid exploration of various design configurations and materials, ultimately leading to more efficient energy conversion systems. This is particularly critical in renewable energy applications, such as electric drivetrains, where improving efficiency directly impacts vehicle range. We capture these effects using the system optimization tool ePOP.

Accuracy is equally important in electromagnetic energy conversion. The intricate nature of these systems demands precise modeling. Automated simulations ensure that every aspect of the electromagnetic interaction is accurately captured, reducing the risk of errors associated with manual inputs. This precision is vital in applications like electric motors and generators, where even small discrepancies can result in energy losses or reduced performance. We automate using JMAGs Python interface.

Cost savings are substantial in this context as well. Developing and testing electromagnetic energy conversion systems can be resource-intensive. Automated simulation workflows cut down on the need for physical prototypes and testing, minimizing material and labor costs. They also facilitate the exploration of innovative materials and design concepts, identifying cost-effective solutions that may have been overlooked in traditional approaches. One example of such a workflow will be featured in the upcoming whitepaper: Optimization and Comparative Analysis of Electric Machine Topologies with Varying Magnetic Materials: Standard Steel Laminations vs. Soft Magnetic Composites, by Dr. Branko Ban.

In the realm of electromagnetic energy conversion, decision-making is often centered around trade-offs between various design parameters. Automated simulations enable engineers to quickly evaluate different scenarios, such as the impact of altering core materials, coil designs, or magnetic field configurations. This data-driven decision-making approach is crucial for optimizing systems in applications like electric drives, transformers and inductors, where efficiency and reliability are critical.

There are collaboration benefits from automated simulation workflows as well. In a field that often involves multidisciplinary teams of engineers, physicists, and materials scientists, these workflows enable real-time collaboration and knowledge sharing. Team members can collectively work on simulation projects, easily exchange ideas, and refine designs, ultimately leading to more robust and innovative electromagnetic energy conversion systems.

In summary, within the context of electromagnetic energy conversion, automated simulation workflows offer efficiency, accuracy, cost savings, data-driven decision-making, and improved collaboration. One example of how we achieve this is listed below:
 

  • Adjusting FEM convergence criteria: +30-100% faster
  • Using advanced FEM solver features: +50-100% faster
  • Using domain decomposition on several CPUs: 10-150% faster
  • Running several cases in parallel: 100-300 % faster

These benefits empower engineers and researchers to develop more effective and sustainable energy conversion technologies, which are essential for the transition to a cleaner and more energy-efficient future.

If you’d like to discuss any of these ideas further, please contact our experts, and we’ll set up a meeting with our technical experts to discuss how your problem could be analyzed faster, and with higher quality.

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11/02/2023
MASTER THESIS ELECTRICAL MACHINE OIL COOLING

YOUR TALENT. OUR OFFER.

About Thesis Work

Thermal management is a key aspect when designing electrical machines in general, and even more so in automotive traction systems. Most electrical vehicles on the road today tend to use water jacket cooling and/or spray oil cooling of some kind. The spray oil cooling typically provides superior performance but comes with the drawbacks of increased cost, weight, and complexity due to the added components (pump, heat exchanger, filter).

The objective for this thesis work will be to evaluate the cooling performance of some novel concepts and compare them to water jacket cooling on an automotive traction electrical machine. The evaluation should preferably contain both simulations and measurements on a prototype of the novel concepts based on an existing electrical machine. A key metric will be the continuous current density for each cooling concept.

Your Profile

You are a (or a plurality of) Master Student(s) in Engineering, you have at least basic knowledge of electrical machines, thermodynamics, fluid mechanics, measurement systems, and manufacturing methods. It will help to have some practical skills as the intention is to build and test.

Communication in English or Swedish is a requirement. The thesis shall be written in English.

Interested?

Don’t hesitate to apply! We look forward to your application!

 

Contact Person

Kristoffer Nilsson, System Architect & Technical Lead, Alvier Mechatronics,

kristoffer.nilsson@alviermechatronics.com

LinkedIn

10/26/2023
Good Environmental Choice toAlvier Mechatronics AB

ENVIRONMENTAL VERIFICAT 2023

Öresundskraft Marknad AB hereby verifies that the above company purchases electricity that meets the criteria for “Good Environmental Choice” as defined by the Swedish Society for Nature Conservation.

 

Electricity labelled Good Environmental Choice means among other things: 

  • The electrical energy included labelled Good Environmental Choice must originate from renewable energy sources, such as hydropower (built before 1996), wind power, solar energy, wave and tidal energy, combustion of biomass or biogas. 
  • Provision is made for funds for environmental improvement measures and reduced energy. 
  • Audits are performed every year (through an authorized, independent and SNF-approved auditor).

LinkedIn

10/20/2023

PASSION & CREATIVITY

Under the motto Passion & Creativity, the Alvier Mechatronics team had 3 really inspiring workshop days from 10 to 12 October. The focus was on team building in a growing, international and thus intercultural team. Based on the DISC method we worked on personal profiles, interaction and our feedback culture, learned cultural related differences in communication. An exciting team building experience was our visit to the Breakout room in Helsingborg.

An all around exciting and inspiring event where we worked on our strategy on the way to 2030 and our next goals for 2024.
Many thanks to everyone involved for their participation and dedication.

Ahoy and the necessary tailwind from passion & creativity for the future!

LinkedIn

07/12/2023

WHICH ARE YOUR KEY METRICS?

Did you know that ePOP can be used to quickly evaluate new technologies in various metrics such as for example cost, efficiency, sustainability, weight and performance?

The example here shows the difference in an EV drive unit between SiC MOSFET and SiC IGBT inverter technology in terms of energy consumption and total cost (drive unit + battery). As expected the SiC MOSFET gives a clear benefit in terms of drive cycle energy consumption, but interestingly it also gives a total cost benefit (due to battery downsizing enabled by the higher efficiency) even though there is an additional cost on the drive unit for this upgrade.

LinkedIn

06/28/2023

POWERING UP A GREEN FUTURE!

Alvier Mechatronics dedicated an afternoon to presentations on the sustainability of drive systems.

Partners were invited as experts for different aspects of sustainability in the development of eDrive solutions to give presentations on them.

 

  • E-machine design for enhanced reyclability and minimised invieronmental impact
  • The road towards sustainable motorsport
  • Embedding sustainability into early stage R&D

LinkedIn

06/22/2023

WE HAVE MOVED!

Are you ready for HETCH?

Are you looking forward to a productive and inspiring exchange in one of the most beautiful co-working spaces in Sweden?

 

Come visit us at HETCH:

  • 14 eDrive brains form Alvier Mechatronics work there on 260 sqm.
  • We will have a prototype assembly area and one prototype validation area.
  • The building is classified Environment building GOLD.
  • We are committed to use renewable energy for electricity and climate control.
  • The connection of the co-working space is excellent.

LinkedIn

02/27/2023

ENGINEERING SOLUTIONS

There are clear trends in motor design such as the sustainable use of resources and sustainability, the reduction of Costs/total costs of the system (TCO), efficiency, less installation space and weight, higher power density, intelligent mechanical and electronical solutions. Our engineering competence leads to the implementation of these trends in motor designs.

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