Cast coil Technology
Next Generation E‑Drives!
flexible in quantity size geometry material
CAST COILS – NEXT GENERATION E‑DRIVES!
A wide range of requirements are placed on the windings of electrical machines. On the one hand, the maximum performance of the electrical machine should be achieved by a high slot fill factor and thus the best possible utilization of the available installation space. On the other hand, the best possible cooling of the conductors must be ensured and the occurrence of additional losses due to current displacement must be avoided. There is an overarching desire for cost-effective and automatable production and assembly of the coils.
We developed a process which allows coils for electrical machines to be manufactured by casting. The coil geometries with flat conductor arrangement which can be manufactured using this process offer decisive advantages over conventionally manufactured windings. The casting production can be carried out either by die casting, low-pressure casting or investment casting and the coils can be cast from copper as well as aluminum.
Goodbye old-fashioned windings – Welcome Cast coils
The benefits of cast coils
Conventional Copper coils
Copper castcoils
Aluminum castcoils
CO2 reduction
Aluminum enables lower energy consumption in production and recycling, 30% lower CO2 emissions and the use of CFC-free refrigerants in refrigeration and air conditioning technology.
CONVENTIONAL COPPER COILS
COPPER CASTCOILS
ALUMINUM CASTCOILS
Performance
Tested electric drives for e-bikes achieved, compared to drives with traditional wound copper coils, up to 50% higher continuous torque with aluminum CastCoils and 100% higher continuous torque with copper CastCoils.
CONVENTIONAL COPPER COILS
COPPER CASTCOILS
ALUMINUM CASTCOILS
Weight reduction
A cast aluminum winding is 40% lighter than a conventional copper winding.
CONVENTIONAL COPPER COILS
COPPER CASTCOILS
ALUMINUM CASTCOILS
Space utilization
Slot fill factor of up to 90% compared to current maximum of 55%.
CONVENTIONAL COPPER COILS
COPPER CASTCOILS
ALUMINUM CASTCOILS
Heat dissipation
Combination of high slot filling factor and excellent thermal behaviour allows to double the current density per slot area.
CONVENTIONAL COPPER COILS
COPPER CASTCOILS
ALUMINUM CASTCOILS
INTRODUCTION OF THE CAST COIL TECHNOLOGY
AND ITS ADVANTAGES
The use of CAST COILS enables electric machines with higher efficiency, higher power and torque density and a greater variety of variants with the same housing with copper coils for high performance and aluminum coils for lightweight solutions due to the higher utilization of installation space and flexible geometry design of the coils. Cast coils contribute to the reduction of energy consumption, e.g. in refrigeration plants by 10%, through higher efficiency and power density. Aluminum in particular enables lower energy consumption in production and recycling, 30% lower CO2 emissions and the use of CFC-free refrigerants in refrigeration and air conditioning technology, which accounts for around 15% of energy consumption in Germany. Furthermore, aluminum can also be used as a recycling material and thus enables closed-loop recycling for the powertrains of the future.
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What we offer
About us
Cast Coil GmbH was notarized on July 18, 2023 in Münster as a spin-off of Fraunhofer IFAM and brings a highly innovative production process for manufacturing coils for electrical machines to the market. The core business is the transfer of technology into production and the licensing of the comprehensive patent portfolio. The young team currently consists of the three founders F.-J. Wöstmann, M. Heuser and Prof. M. Busse. All of them are significantly involved in the development of Cast Coils and are distinguished by their entrepreneurial activities and networks in addition to their scientific background.
