We are witnessing huge global shifts towards cleaner growth and more resource efficient economies. The drive to lower carbon emissions is resulting in dramatic changes in how we travel and the ways we generate and use energy worldwide. Electrical machines are at the heart of the accelerating trends in the electrification of transport and the increased use of renewable energy such as offshore wind. To address the pressing drivers for clean growth and meet the increasing demands of new applications, new electrical machines with improved performance - higher power density, lower weight, improved reliability - are being designed by researchers and industry. However, there are significant manufacturing challenges to be overcome if UK industry is going to be able to manufacture these new machines with the appropriate cost, flexibility and quality. The Hub's vision is to put UK manufacturing at the forefront of the electrification revolution. The Hub will address key manufacturing challenges in the production of high integrity and high value electrical machines for the aerospace, energy, high value automotive and premium consumer sectors. The Hub will work in partnership with industry to address some common and fundamental barriers limiting manufacturing capability and capacity: the need for in-process support to manual operations in electrical machine manufacture - e.g. coil winding, insertions, electrical connections and wiring - to improve productivity and provide quality assurance; the sensitivity of high value and high integrity machines to small changes in tolerance and the requirement for high precision in manufacturing for safety critical applications; the increasing drive to low batch size, flexibility and customisation; and the need to train the next generation of manufacturing scientists and engineers. The Hub's research programme will explore new and emerging manufacturing processes, new materials for enhanced functionality and/or light-weighting, new approaches for process modelling and simulation, and the application of digital approaches with new sensors and Industrial Internet of Things (IoT) technologies.

Electrical machines are estimated to contribute to more than 99% of the global generation and 50% of all utilisation of electrical energy. Electric motors and generators will underpin the transition towards a more sustainable carbon neutral economy being at the heart of renewable energy generation in wind and marine power systems. They will also contribute to significant changes in our life as low emission transportation systems with "more electric" or "all electric" technologies in the automotive, marine, railway and aerospace industries are quickly growing in a market conservatively estimated to be worth over £50bn. Reliability is of paramount importance for the acceptance of electrical drives in safety critical applications such as those in aerospace industry. Increased reliability and availability can also generate significant commercial benefits to operators and users in sectors such as industrial, transport (e.g. electric/hybrid vehicles) and renewables (e.g. offshore wind generators) where the cost of maintenance, downtime and repair can markedly affect the business case for adopting new and innovative technologies. Electrical faults in machines, usually caused by progressive degradation of insulation materials, accounts for over 40% of the reported failures in industrial installations. To increase availability without increasing maintenance and associated downtime, it is necessary to monitor machines during operation, autonomously, with well-founded information on the current state of machine health available in real-time to the operator. Robustness of the methods for assessing degradation is critical, since false-positives, i.e. condition alerts which do not reflect the actual condition of elements of the machine, can be equally damaging in terms of availability and operational costs. Unfortunately, universally accepted and industrially validated methods for online condition monitoring remain elusive due to their lack of generality and robustness, the need for tuning specific algorithms for each individual application or the requirement for invasive and costly off-line testing. The research has two main aims that will contribute to a unified solution for online condition monitoring of inverter-driven electric machines. The first is the determination of a quantifiable model of lifetime of electrical motors under realistic operating conditions, including thermal, electrical and thermo-mechanical stresses, informing a methodology that can be used in real-time applications for continuous indication of the remaining useful life. The second is the demonstration of an innovative concept for condition monitoring of the state-of-health of the machine insulation without the need for additional expensive testing hardware, or modification to existing drives. The method, based on the real-time measurement of the common-mode impedance of the machine and its variations over the lifetime of the drive system, can provide a quantifiable indication of the progressive degradation of the insulation material. The research will allow a cost-effective solution to significantly improve reliability and operating costs in a large number of potential applications including transportation and renewable energy generation.

Rapid and transformative advances in power electronic systems are currently taking place following technological breakthroughs in wide-bandgap (WBG) power semiconductor devices. The enhancements in switching speed and operating temperature, and reduction in losses offered by these devices will impact all sectors of low-carbon industry, leading to a new generation of robust, compact, highly efficient and intelligent power conversion solutions. WBG devices are becoming the device of choice in a growing number of power electronic converters used to interface with and control electrical machines in a range of applications including transportation systems (aerospace, automotive, railway and marine propulsion) and renewable energy (e.g. wind power generators). However, the use of WBG devices produces fast-fronted voltage transients with voltage rise-time (dv/dt) in excess of 10~30kV/us which are at least an order of magnitude greater than those seen in conventional Silicon based converters. These voltage transients are expected to significantly reduce the lifetime of the insulation of the connected machines, and hence their reliability or availability. This, in turn, will have serious economic and safety impacts on WBG converter-fed electrical drives in all applications, including safety critical transportation systems. The project aims to advance our scientific understanding of the impact of WBG devices on machine insulation systems and to make recommendations that will support the design and test of machines with an optimised power density and lifetime when used with a WBG converter. This will be achieved by quantifying the negative impact of fast voltage transients when applied to machine insulation systems, by identifying mitigating strategies that are assessed at the device and systems level and by demonstrating solutions that can support the insulation health monitoring of the WBG converter-fed machine, with support from a range of industrial partners in automotive, aerospace, renewable energy and industrial drives sectors.