Cast Coil: Unlock the future of pedelecs
Cast coils are revolutionizing pedelecs. They enable more compact and lighter motors with higher performance and improved efficiency, see Part 1-7. This leads to a number of advantages for riders and manufacturers:
Challenges for pedelec motors:
- Compact design
- Lightweight construction
- High efficiency
- Self-cooling – no need for forced cooling
- Cost-effective
- Sustainable
- Wide range of applications and variants
What can Cast Coil provide?
1. Compact design
Due to the higher fill factor, the motor housing can be reduced in size and still deliver the same performance with higher efficiency. The higher efficiency increases the range and the smaller installation space improves visual integration.
2. Lightweight construction
Cast coils offer two possibilities for weight reduction when using Al-cast coils. By substituting wound Cu coils with cast Al coils, the weight of the coils is reduced by up to 60% and better performance is delivered at the same time. By reducing the overall installation space of the motor, the lightweight construction is transferred to the entire motor. – Both variants can be combined with each other and thus provide new design freedom for lightweight construction!
3. High efficiency
The efficiency is increased with both Cu-Cast coils and AL-Cast coils, which results in an increase in range with the same battery capacity. Instead of a higher range, the battery capacity can also be reduced, thus reducing the costs and the overall weight of the pedelec.
4. Self-cooling – no forced cooling
Pedelecs in particular, and even more so cargo bikes, require very good cooling and heat dissipation from the motor in order to prevent the motor from being overloaded when riding uphill, for example. Thanks to the improved heat distribution within the coil and heat dissipation to the laminated core, Cats Coils completely eliminate the need for forced cooling or additional oil as a cooling medium. – This makes the design simpler, maintenance-free, more fail-safe, lighter and more cost-effective, even for the highest loads!
5. Cost-effective
Due to the advantages described in points 1-4, cast coils offer the possibility of reducing costs and weight in the overall pedelec system, from the coils to the motor to the battery!
6. Sustainable
The use of Al as a coil material enables a lower CO2 footprint and, with regard to the motor, easier recycling due to the lower material depth and the lower energy requirement in recycling.
7. Wide range of applications and variants
By using copper and aluminum as material variants, cast coils enable a high-performance variant and, when using aluminum cast coils, an ECO variant with lower weight and CO2 footprint in the same motor housing. This means that different variants for a wide range of applications can be implemented with one motor design and scale effects can be achieved.
