Automotive Technology R & D Laboratories is working on the development of a next-generation motor that incorporates a powder magnetic core. A compact and efficient motor is desired in every application area, such as automobiles and home appliances, since such a motor has a direct impact on performance aspects such as fuel economy and power consumption, and ultimately on environmental protection. The key technology for motor size reduction and efficiency improvement is the powder magnetic core, whose flexibility of shape makes it ideal for motor size reduction. However, overall progress in motor improvement is not based on powder magnetic core advances alone. The magnet wires, another primary motor component, must advance as well. This is the aspect I am working on.

Although motor performance increases with the number of turns of magnet wire, the motor size also increases. As a solution to this problem, I optimized the shape and size of the magnet wire for more efficient winding in a limited space.

Simple size reduction alone is not enough to launch a motor on the market. Maintaining high performance in addition to reduced size is of vital importance. A motor comprises a core, power supply components and other parts, in addition to magnet wires. Our team made concerted efforts toward reducing motor size while also improving performance.

Key tasks in regard to the magnet wire were processing techniques by which to optimize the shape, and heat resistance verification. Through a process of trial and error we set processing conditions so as not to diminish the important insulating properties of the magnet wires. As regards heat resistance, in-vehicle motors must operate in a demanding environment. We tested the magnet wires for reliability, establishing a new evaluation system and reproducing situations as similar as possible to the actual in-vehicle environment.

Sumitomo Electric has more than 100 years of history in dealing with copper wires. This is very useful for our present development activities. For instance, when I come up against a problem and need a hint as to a solution, I search through in-company materials, where I can find useful information in documents written decades ago. Our forerunners’ research and the records of their research results are now invaluable assets for us, though at the time they were recorded those data were not contributing to commercialization.

Moreover, many present-day employees have a wealth of practical knowledge. Theories on paper alone are not enough. Wisdom developed in the field is essential. Thanks to the Company’s long history, we can obtain information from those who have the practical knowledge and wisdom, and can make the best use of such information in our development process.

Although in research and development we may still be in the trial and error stage, we are strongly aware of society’s expectations. I hope to deliver environment-serving products to the world as soon as possible.