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AML
Company OverviewElectrical Machine Development
PM-WireTM - A New, Large and Sustainable American Industry
December 2019
E300938 ©2019 Advanced Magnet Lab, Inc. All rights reserved worldwide.
Reimagining the Magnet Technology that Drives the World
AML Product development company supplying magnet solutions for startups, Fortune 100 and Global 2000 companies
AML’s customers are the road-to-market for end product Revenue includes design contracts, prototyping & grantsRecurring revenue from licensing and manufacturing
AML focuses on what AML does best, MagnetsThe “enabler”, the “magnets Inside” (i.e. BASF, Intel)
AML technology includes software and hardwareThe most advanced existing and clearly differentiatedSignificantly improves performance at a lower cost
AML’s market experience is diverse – Our growth plan is focused!Bringing to market unprecedented performance and economics for electric propulsion
ü PM-WireTM – Breakthrough technology for manufacturing of permanent magnetsü PM-360TM – Unprecedented performance and economics for motors and generators
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Our Company
AML’s Technology PlatformProprietary software, magnet &
manufacturing technologies
EV UAV eVTOL Aircraft Ships MedicalWind EnergyMining Consumer
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Diverse Sector Experience
Oil Exploration
Oil & Gas
Chilean Joint VentureMining & Environment
Mining & Minerals
Wind Turbine Generators
Power Generation
Cancer Treatment
Heart Disease
Medical
Rapid Deployment for Oil Spill Containment
Water & Environment
Superconducting Accelerators
Research
Radiation Shielding
Space
Permanent Magnet Manufacturing
Manufacturing
Electric Propulsion
Transportation
Motor & Generators
Energy Use
ELECTRICAL MACHINES
Transportation is Going All Electric or Hybrid-Electric
Replacing Engines with Electric Motors
Motors are Driven by Magnets
Transportation is Driven by Magnets
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E-mobility - The electrification of transportation
Motor
Magnets are the beating heart of e-mobility
Revenue is generated through design contracts, building prototypes, licensing and manufacturingü AML focuses on what AML does best – Magnets ü AML sells direct to customerü AML’s overhead is minimal. Business scales with applications engineering, not manufacturingü AML contract manufactures or joint ventures for high-rate manufacturing
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Scalable Business Model
Customer
Customer Acquisition Sales
ApplicationsEngineering
Prototypes &Low-Rate Mfg.
High-Rate ManufacturingJoint Venture or
Contract Mfg.
Solution Requirements
AML Engineered SolutionMOEMTM – CoilCADTM – Magnet Technology
AML Low Rate ManufacturingCNC & 3D Printing
PM-360TM
Rotor Magnet
Electric Motors
Intellectual PropertyComprehensive - enabling software, magnet and manufacturing technologiesUS/Intl. Patents – 28 Granted, 22 in process (12/2018)
Software – Proprietary and Enablingü Coil-CAD™ Design & Manufacturing ü MOEM™ Electrical Machine Modeling Software
Revolutionary magnet technologiesü Perfect-Field MagnetsTM
ü PM-WireTM & PM-360 Permanent MagnetsTM
ü Proprietary manufacturing processes
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Our Differentiation - IP
AML Patents
CoilCADTM
Proprietary magnet design software
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MOEMTM
Proprietary electrical machine design softwareAML Magnet Technologies
Unprecedented capabilities and performance
AML’s Technology PlatformWe are differentiating with unique capabilities and unprecedented technical advances in the application of magnetics
AML is the world’s best at optimizing magnetic applications!
Competitors like GE, Siemens, and ABB utilize conventional magnet technologies which fundamentally have not changed since first invented in the late 1800s
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Our Differentiation – Electromagnets
AML’s Perfect-Field™ Application Development Process & Magnet Technologies
Nikola Tesla’s Induction MotorCirca 1883
Competitors Technology19th Century
AML “Perfect-Field Magnets” provide the “highest field quality” availableDisrupts the mainstay solution, Helmholtz Magnets
ü Up to 40X improved magnetic field qualityü > 200% increase in magnetic fieldü > 50% less footprintü > 40% less powerü 1, 2 and 3-axis solutionsü Equivalent Cost
Marketsü Electrical Machinesü Quantum Computing ü Medical ü Research ü Manufacturing
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Our Differentiation – Electromagnets
Perfect-FieldTM Development ProcessProprietary software, magnet & manufacturing technologies
Helmholtz MagnetsMainstay solution since the 1800s
Hermann von Helmholtz (1821-1894)German scientist and philosopher who
made fundamental contributions to physiology, optics, electrodynamics,
mathematics, and metrology
“Good Field Region”Small Spherical Area1% Field Variation
B ~ 2 Gauss (4 times Earth Magnetic Field)Field Variation in Good Field Region: 1 %
Field Variation in “Good Field Region”: less than 0.001 % B ~ 50 Gauss (100 times earth magnetic field)
Double-HelixTM CCT – Continuous Cosine ThetaSaddle Coils
CCT with Shape Shimming
A new permanent magnet (PM) technology, named PM-Wire™Reduces the cost, increases the reliability and enables new applications
Process allows highly automated, safe, mass-produced PM components, including complex and “wire like”, shape forms
Benefits of PM-Wire™ü Greater Performance – precise magnetization / magnetic flux directionü Consistent & Higher Quality – precisely controlled and automated manufacturingü Flexibility - unrestrained shapes & sizesü Increase Structural Integrity – high RPM motors/generatorsü Enables Cooling – jacket seals and protects PM materials from cooling mediaü Higher Reliability – more robust PM components and PM assembliesü Easier and Safer – simplified manufacturing of PM based productsü Lower Cost Manufacturing – mass produced, in process forming of cross-section, long length pieces and
increases PM material yield (10%-30%)
PM-360TM – Enabled by PM-WireTM
A configuration PM-WireTM which significantly improves the performanceand lowers the cost of motors, generators, magnetic gearboxes, magnetic bearings, levitation, manufacturing and more
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Our Differentiation – Permanent Magnets
AML’s PM-Wire™ & PM-360TM
Manufacturing Process
PM-360TM vs. Conventional
PM-360TM - Wins!ü Highest usable field in the gap between motor rotor and statorü Single-Magnet with the optimum magnetizationü Eliminates the need for iron (weight)ü Increased efficiency, higher torque, less vibrationü Intrinsic containment of centrifugal forces in high RPM machinesü All, at a significantly lower cost
Conventional ü North-South Magnetization - 50% of field is unusedü Requires 100s of individual magnets ü Requires Iron / Steelü Requires containment of centrifugal forcesü High cost to produce and assemble
PM-360TM
~57% Field Increase
N S
Conventional N-S Pole Magnetization
MOEMTM + Perfect FieldTM + PM-WireTM = Best Electrical Motors
1. MOEM™ - Multi-Objective Electrical Machine Softwareü Complete design exploration to determine the optimum motor or generator configuration
2. CoilCADTM - Perfect-Field™ Statorsü AML’s CoilCAD™ software and magnet technologies provides the optimized design and
manufacturing of stators and magnetization of PM-Wire™
3. PM-360™ Rotorsü Enabled by PM-WireTM, PM-360TM provides the optimized permanent magnet rotors
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AML Differentiation - Enabling IP for optimized propulsion motors
Customer RequirementsPropulsion Motors
MOEMTM
Optimized Machine Configuration
MOEM™
CoilCAD™ - Perfect Field CoilsOptimized Stator Design & PM-360TM Magnetization
AML PropulsionOptimized Rotors & Stators
Video
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PM-WireTM - Enabling better magnet-based products
~57% Field Increase
Manufacturing PM ProductProcessingMining Rare Earth Materials
End ProductsMotors and Generators Magnetic GearboxesMagnetic SeparationBeam lines, NMR, MRIManufacturing, Assembly EquipmentCell phones, iPads, Data Security
Value PropositionSignificantly improve performance
ü ~10% to ~50%
Market SizeMotors – $200B / 2025PM-360TM – $25B/2018 - $46B / 2025
Market SectorsE-Mobility – Auto, Aero, Marine, RailWind EnergyOil& Gas, MiningIndustrial
ManufacturingHigh QualityHigh YieldHigher PerformanceHighly AutomatedHigh Throughput
EV UAV eVTOL Aircraft Ships MedicalWind EnergyMining Consumer
Existing Drone MotorsPlug-and-play. No Change to motor design
ü ~10% Torque IncreaseDesign Change to Stator
ü ~30% Torque IncreaseLower cost
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Performance Improvement Examples
Conventional
New Motor DesignPM-360TM Dual Rotor Configuration
ü 30% Plus Improved Performance
Specifications1000 Nm @ 2500 RPM (261 kW)Liquid cooledMaximum frequency 1200 Hz400 V line voltageOD < 420 mm
PerformanceOD=0.415 m / L=0.12 m95.3 % efficiency @ 261 kW25.5 kg active mass (< 30 total mass)
Specific torque > 33 Nm/kgSpecific power > 8.7 kW/kg
Final materials selection, mechanical and cooling design and prototype demonstration will impact the final performance characteristics
Electric Vehicles MotorsPM-360TM Dual Rotor Configuration
ü 30% to ~50% Improved Performance
U.S. Department of Energy Goals125kW / 20,000 RPM motor (BMW i3 Baseling Example)
ü 8X Power Density Improvement§ Today, AML can achieve > 30 kW/L @ 98% efficiency with air cooling§ Today, AML can acheive > 40 kW/L @ 98% efficiency with liquid cooling
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Performance Improvement Examples
Optimizing magnet-based products and solutions
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AML Today - Transforming industries and companies
Development Partners
History of Successful Execution
e-MobilityDevelopment Programs
On-BoardingPrograms
Perfect-Field Magnets
Global Power Tool Companies
E-Mobility
Consumer
Drone / UAV / Aircraft
PM-WireTM
Sky Way Systems Development CompanyGlobal Motor ManufacturesEV and Aircraft Manufacturers
U.S. ArmyCommercial Drone CompaniesConsumer Drone Companies
eVTOLsPropulsion
Turbo-Electric Propulsion
U.S. Defense CompaniesU.S. Mining CompaniesU.S. Department of DefenseGlobal 2000 Heavy Industries Company
Drone Motors
Quantum Computing
Research
Medical
Electrical Machine DevelopmentDesign and optimization of motors and generators
Reimagining the Magnet Technology that Drives the World
E-Propulsion Requirements1000 Nm @ 2500 RPM (261 kW)Liquid cooledMaximum frequency 1200 Hz400 V line voltageDual rotor ironless configuration
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Example – AML vs. World Record
3-phase air-core concentrated stator winding with direct cooling
Outer PM-360TM rotor
Inner PM-360TM rotor
Example of a dual-rotor motor configuration
Magnetic Flux Density Distribution
Specific power > 5 kW/kg
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Optimizing Electric Machines
Machine specificationsPowerRPM
Voltage
Design parametersRiP
HA thicknessHAratio
NbTurns/phasehStatorStator ff
Stator gapAir gap
Heat transfer coefficients
Design constraintsMax velocity
Max temperatureVariables bounds
Material propertiesPermeability
Thermal conductivityElectrical conductivityMechanical strength
MOEM™
Machine configurationType of analysis
Design Space Exploration
Partially funded and developed for NASA
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Analysis-Led Design– Parameter Selection and Trade-offs
Low Mass Designs
High Efficiency Designs In-Between Designs
Selected design for further optimizationüOD=0.415 m
ü L=0.12 mü 95.3 % efficiency @ 261 kWü 25.5 kg active mass (< 30 total mass)
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Design Trends and Example
ü > 33 Nm/kgü 95.3 % efficiency @ 261 kW
ü 140 C Stator nominal temperature with 9 L/min water flow @ 50 C
ü > 200 % overloading capability continuous
Parameter Value
Nominal Power 260 kW
Nominal Torque 1000 N.m
Nominal Efficiency ~ 95 %
OD 0.41 m
Length 0.13 m
Estimated mass ~30 kg
Specific Torque > 33 Nm/kg
Specific Power > 8.5 kW/kg
Cooling Liquid cooled
Peak temperature (stator at nominal operation)
140 C
Rotor containment thickness (assuming carbon fiber composite)
Inner rotor – ~ 1 mmOuter rotor - ~ 2 mm
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Example of Motor Parameters
Geometry (Active Components) Magnitude of B, B vector and Current Density Distribution
Magnitude of B and B vector
30% Plus ImprovementSpecific power > 8.7 kW/kgSpecific torque > 33 Nm/kg
PM-WireTM & PM-360TMSignificantly improves the performance and lowers the cost
of permanent magnet based products
Reimagining the Magnet Technology that Drives the World
Today, it is mostly China
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Building a strategic supply chain in the U.S.
Rare Earth MaterialsNdPr
End-ProductsRE Oxide Production
Cracking and Solvent Extraction
End-Use Applications
China Produces 90+% Permanent Magnets
Magnet Production
Physical SeparationMining
Rare Earth Supply
Magnets
Mineral Concentrate Ready to Ship from the U.S. to China
Cancer, Lung DiseaseEntire Villagees are Destroyed
RE Metal and Alloy Production
Strip CastingCorse Crushing
Hydrogen DecrepitationJet Miling
Magnet Powders
Metal Alloys
Laborious, low-yield, low-quality, limited in size, limited in performance optimizationProduced mostly in China and Malaysia
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Today – Magnet manufacturing is archaic
ProcessingMining Rare Earth Materials
A new permanent magnet (PM) technology, named PM-Wire™Reduces the cost, increases the reliability and enables new applications
Process allows highly automated, safe, mass-produced PM components, including complex and “wire like”, shape forms
Benefits of PM-Wire™ü Greater Performance – precise magnetization / magnetic flux directionü Consistent & Higher Quality – precisely controlled and automated manufacturingü Flexibility - unrestrained shapes & sizesü Increase Structural Integrity – high RPM motors/generatorsü Enables Cooling – jacket seals and protects PM materials from cooling mediaü Higher Reliability – more robust PM components and PM assembliesü Easier and Safer – simplified manufacturing of PM based productsü Lower Cost Manufacturing – mass produced, in process forming of cross-section, long length pieces and
increases PM material yield (10%-30%)
PM-360TM – Enabled by PM-WireTM
A configuration PM-WireTM which significantly improves the performanceand lowers the cost of motors, generators, magnetic gearboxes, magnetic bearings, levitation, manufacturing and more
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Introducing PM-WireTM
AML’s PM-Wire™ & PM-360TM
Manufacturing Process
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PM-WireTM - Enabling better magnet-based products
~57% Field Increase
Manufacturing PM ProductProcessingMining Rare Earth Materials
End ProductsMotors and Generators Magnetic GearboxesMagnetic SeparationBeam lines, NMR, MRIManufacturing, Assembly EquipmentCell phones, iPads, Data Security
Value PropositionSignificantly improve performance
ü ~10% to ~50%
Market SizeMotors – $200B / 2025PM-360TM – $25B/2018 - $46B / 2025
Market SectorsE-Mobility – Auto, Aero, Marine, RailWind EnergyOil& Gas, MiningIndustrial
ManufacturingHigh QualityHigh YieldHigher PerformanceHighly AutomatedHigh Throughput
EV UAV eVTOL Aircraft Ships MedicalWind EnergyMining Consumer
32
PM-WireTM – Stage of Development
Phase 1 – Complete - AML validated the process using Isotropic (bonded) Phase 2 – Complete November 2019 - Validating the Phase 1 process for Anisotropic Sintered Powder
Phase 3 – Complete 2020 - Following Step 2, AML will validate Anisotropic Sintered
Isotropic PowderBonding Agent
No Sintering
AnisotropicNo Bonding Agent
Sintering
Br (T)Flux Density
Magnetic FieldNdFeB
Anisotropic PowderNo Bonding Agent
No Sintering
MQA-36/37/38
Phase 1 Phase 2 Phase 3
AML Market
Tomorrow, in the U.S.
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Building a strategic supply chain in the U.S.
Physical SeparationMining
Rare Earth Supply
Mineral Concentrate Ready to Ship to the U.S.
Rare Earth MaterialsNdPr
RE Oxide Production
Cracking and Solvent Extraction
RE Metal and Alloy Production
Strip CastingCorse Crushing
Hydrogen DecrepitationJet Miling
Magnet Powders
Better Magnets Production
Better End-Products
BetterEnd-Use Applications
Metal Alloys
AML Melbourne, [email protected]
Mark Senti, [email protected]
AML-Enabled.com
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TRANSFORMING MAGNET TECHNOLOGY. DRIVING A GLOBAL MARKET.
EV UAV eVTOL Aircraft Ships MedicalWind EnergyMining Consumer