Innovations high performing motion systems
Discover our latest innovations in high performing motion systems
Vehicles and machines are made of moving parts. To make them perform better, we not only focus on product architecture, energy efficiency and management, but also look at how we can improve electric motors and drives and make them more comfortable to use.
Other themes:
Improved powertrain performance with the help of hybrid policy learning
Conventional powertrain controllers generally cope well with changing operational conditions. However, they are often not flexible enough when new conditions arise.
Using machine learning, we have been able to improve the performance of these controllers in complex industrial powertrains by harnessing real-time data. Our hybrid architecture allows us to deploy reinforcement learning, resulting in a very capable controller. By itself, however, this architecture is not very safe to use. We solve this by combining it with a conventional controller. In this way we use the robustness of the controller as leverage so that it can handle changing circumstances, while the extensive adaptability of our data-driven "reinforcement learning" controller will ensure that it can adapt to new circumstances.
Body control over speed bumps
When driving, we all have to deal with speed bumps or potholes. This is not very comfortable. In order to absorb these shocks, most cars are equipped with a passive damping system. Some cars from the higher segment are equipped with active damping, which allows you to determine the driving characteristics and comfort level yourself. Besides suspension, electric motors also have an influence on the comfort and handling of a (hybrid or electric) car.
For this reason, we investigated a combined control of both electric motor and active damping system. The aim of this combined control is to achieve a higher comfort level compared to the standard separate control. By applying this technique, we were able to reduce the shock when driving over a speed bump by 25% and to reduce the stabilisation time after driving over the threshold by 35%.
Electric motor with integrated magnetic spring
Electric motors consume +/- 45% of the energy produced worldwide and account for +/- 60% of total industrial energy consumption. It goes without saying that a small reduction in this consumption not only represents a major cost saving, but also has a major impact on the environment.
Some applications have a cyclic and highly variable low-torque profile, in other words, a high peak-to-average torque ratio. Examples are looms, presses, robots, compressors and pumps. This low torque profile has a negative impact on the size, efficiency and energy consumption of the motor. For these types of applications, we introduce an innovative electric motor with integrated magnetic spring.
This solution is not only compact but also energy-saving as the magnetic spring provides torque in a passive way. The amount of energy saved depends on the design of the magnetic spring and the low torque profile. But in our example, energy consumption is reduced by +/- 60% compared to a conventional motor drive without a magnetic spring.
Electric motor with integrated power electronics
Electric drives are becoming smaller, more powerful and more economical. It is in this context that we have integrated the power electronics into an electric motor so that they share a cooling mechanism and mechanical structure.
By pointing a thermal camera at an electric motor, we were able to get a clear view of the temperature of the various components. This allowed us to see the thermal response of the motor, the power electronics and the cooling system. By sharing the cooling system, we achieve a weight saving of 10 to 20% compared to separate cooling systems for engine and electronics.
Improved energy efficiency through context adaptive control applied to a hybrid vehicle
The conditions in which a machine or vehicle operates can have a negative impact on its performance and fuel consumption. Yet most standard drive controllers are pre-programmed to act in a certain way, defined in advance. This does not take into account factors such as the environment or the state of the road.
In order to increase the overall efficiency of machines and vehicles that face changing operational conditions, Flanders Make has developed a new context-adaptive control strategy. This strategy detects and characterises the operating conditions based on the sensor data of the vehicle and then adjusts the control parameters of the vehicle. In a test with a hybrid vehicle in which we let the controller control the interaction between the electric motor and the combustion engine, we see that on average we consume 1% less fuel compared to a standard benchmark controller.
DC network for power management of multiple machines
Traditionally, electricity distribution in businesses is carried out with AC networks. Yet innovative DC networks offer several advantages: they can handle bi-directional power flows more efficiently; they eliminate several steps to convert power; and it is easier to integrate buffer elements and/or storage systems into the network.
We have developed a DC network that allows machines to exchange energy simultaneously, resulting in energy efficiency gains for the entire company. In a DC network, energy can come from different sources such as the mains, renewable energy sources and/or fuel cells. It can then be distributed to different consumers such as your machinery. This system can be implemented in existing production environments by replacing a number of components. In addition, some common components from an AC network are no longer needed in a DC network. This results in a simplified power network. DC networks in industry thus lead to fewer losses and a potentially lower investment cost.
Modular motion system
To improve performance and flexibility in moving mechanical systems, we have developed an alternative architecture that uses distributed and modular actuation. The purpose of this architecture is to demonstrate better performance of moving systems with modular actuation.
By using distributed actuation, we can greatly increase the speed of back-and-forth movements. This principle affects both performance (which improves due to lower inertia) and the dynamic limitations of the system. By comparing a non-modular and a modular reference on a sliding pendulum mechanism, we can demonstrate the internal dynamics level. We find this kind of movement in weaving looms or packaging machines, for example. These highly dynamic applications benefit from the modular motion system.
Our results show that our system is cost-neutral at the system level. A modular actuation provides an increase in speed of 40 to 50%, and offers "single failure handling" without losing full functionality.
Multifunctional power electronics converter
Electric vehicles have many advantages. They have fewer parts susceptible to wear and tear, are more environmentally friendly, quieter, fiscally interesting, etc. But because of the heavy battery packs, they are heavier than vehicles with an internal combustion engine (ICE). This extra weight has an impact on driving characteristics, driving range and wear and tear on components such as brakes and tyres. In the constant search for smaller, lighter and better-performing electric drive trains, we developed an integrated drive system that combines higher power with better functionality. This multifunctional concept has an inverter that performs several operating modes. This results not only in lower costs, but also in a 40% weight and volume reduction for the power electronics inverters in an electric powertrain. Equally important, we increase the efficiency and reliability of the powertrain. In addition, we extend battery life, which reduces battery maintenance costs over the life of the vehicle.
In this way, we reduce both the initial and operating costs of the vehicle. In addition, these improvements to the multi-functional power electronics inverter will ensure a smoother transition from conventional ICE vehicles to plug-in hybrids to electric vehicles.