New Electric Midibus By Dana/Karsan Driving Use of Rare Earth Permanent Magnet Growth

Dana Karsan midibus

TBB Staff | Sep 24, 2018

Dana Incorporated and vehicle manufacturer Karsanrecently unveiled the Karsan ATAK electrified midibus featuring Dana’s TM4 SUMO MD electric motor and inverter.

Karsan, a manufacturer of light commercial vehicles, shuttle buses and city buses, is focused on providing contemporary product and service solutions for mass transportation. The company has been developing sustainable electric-driven vehicles since 2015 and introduced its first prototype electric minibus, the Karsan JEST, in 2016.

“Globalization, increased environmental concerns and the need to reduce operating costs continue to drive our innovative thinking,” said Christophe Dominiak, chief technology officer for Dana. “As Dana expands its capabilities and the scope of product offerings for electric vehicles, we are pleased to be working with industry leaders like Karsan, which has extensive vehicle development and manufacturing expertise.”

The electrified bus is based on the Karsan ATAK eight-meter low-entry bus platform and is equipped with a TM4 SUMO MD electric motor and inverter. The TM4 SUMO MD is composed of a high-torque, permanent magnet variable reluctance (PMVR) direct drive motor and automotive-grade power electronics. The new motors with the PMVR technology for external rotors can deliver 45 percent more torque and operating speed than previous motors in the same compact package, while reducing cost.

PMVR works by adding specially designed soft magnetic composites (SMCs) next to the magnets. SMCs are produced through a new forming process and fabrication method by TM4. The SMCs also allow the use of simpler and smaller magnets that are easier to manufacture and uses less rare-earth in the fabrication process to account for 25-percent savings in magnetic material.

This new bus platform can operate with a range of up to 300 kilometers (186.4 miles) on a single charge. Dana also is a key contributor in the development of the vehicle control software, through the supply of hardware and services related to its TM4 NEURO 200 vehicle control unit platform and SynApps development tool.

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