Periodic Reporting for period 1 - MultiMag (Multi-functional, multi-material magnetic components and structures for electrification)
Berichtszeitraum: 2022-12-01 bis 2024-05-31
Europe has ambitious targets for reducing emissions to mitigate and ultimately stop climate change. Electrification of mobility and other sectors is crucial achieving these goals, with electric motors and drives play key role. Despite decades of development, electric motors still face compromises in their performance, power vs. weight, use of materials etc. While electric motors can be manufactured without permanent magnets, the most powerful motors are based on those magnets, which often require Rare Earth Elements (REE) materials. To effectively fight climate change, we need to develop electric motors, which are more effective, lighter and use less REE materials. Due to dominance of international players related to REE magnets, it is also important to improve recycling of those materials in Europe.
The overall objective of MultiMag is to develop a holistic approach to additively manufacture multi-material, multi-functional structures, and components for electric machines. This will lead to remarkable advances in their performance, light weighting, and lead time. At the end-of-life, valuable materials can be effectively recycled. This endeavor is based on innovations in design, materials, multi-material additive manufacturing (MM-AM) processes, and end-of-life operations. Quantitative targets include a 50% mass reduction of magnets and a 20% reduction inactive motor components, a 30% improvement of overall performance, a 20% reduction of rotor manufacturing lead-time, a 20% increase in energy efficiency, and a recyclability rate over 60%.
The overall objective of MultiMag is to develop a holistic approach to additively manufacture multi-material, multi-functional structures, and components for electric machines. This will lead to remarkable advances in their performance, light weighting, and lead time. At the end-of-life, valuable materials can be effectively recycled. This endeavor is based on innovations in design, materials, multi-material additive manufacturing (MM-AM) processes, and end-of-life operations. Quantitative targets include a 50% mass reduction of magnets and a 20% reduction inactive motor components, a 30% improvement of overall performance, a 20% reduction of rotor manufacturing lead-time, a 20% increase in energy efficiency, and a recyclability rate over 60%.
The project has defined three Use Cases (UC), representing three different types of electric motors. The first UC is a general-purpose induction motor with applications in automation and mobility. The second motor is a novel synchronous permanent magnet brushless motor with axially aligned stator poles, having applications in e-mobility. The third UC is a multipurpose electrical rotary actuator i.e. structurally representing brushless DC motor, having use in new space applications. Detailed key performance indicators (KPIs) have been defined for each motor according to their development needs.
Based on simulation and modelling, we have identified and analyzed various components and structures of these use case motors to find the most promising development opportunities. Several approaches have been carried out and components have been examined numerically. Significant improvement potential has been identified, related to the weight reduction of magnets through the re-design of certain components and the utilization of geometrical freedom from additive manufacturing.
Parallel to design, the project has progressed to develop materials and material pairs for multi-material additive manufacturing technologies. We focus on four types of materials, each of them essential in electric motors: soft magnets; permanent magnets; insulators; and structural materials. A key activity is to create multi-material structures with relevant material pairs, such as soft magnetic / insulating or non-magnetic material; and permanent magnet / insulating or soft magnetic materials. The target is to create fault-free structures that fulfill the functional requirements. During the second period, the project will select and manufacture demonstration components and structurers, testing them in an industrially relevant environment.
To ensure sustainability of developed solutions, Life Cycle Inventory data has been gathered from base line solution motors, which will later be compared to MultiMag solutions. In addition, recovery, leaching and oxide reduction technologies for materials like neodymium used in permanent magnets, have been further developed to ensure effective recyclability of REE materials.
Based on simulation and modelling, we have identified and analyzed various components and structures of these use case motors to find the most promising development opportunities. Several approaches have been carried out and components have been examined numerically. Significant improvement potential has been identified, related to the weight reduction of magnets through the re-design of certain components and the utilization of geometrical freedom from additive manufacturing.
Parallel to design, the project has progressed to develop materials and material pairs for multi-material additive manufacturing technologies. We focus on four types of materials, each of them essential in electric motors: soft magnets; permanent magnets; insulators; and structural materials. A key activity is to create multi-material structures with relevant material pairs, such as soft magnetic / insulating or non-magnetic material; and permanent magnet / insulating or soft magnetic materials. The target is to create fault-free structures that fulfill the functional requirements. During the second period, the project will select and manufacture demonstration components and structurers, testing them in an industrially relevant environment.
To ensure sustainability of developed solutions, Life Cycle Inventory data has been gathered from base line solution motors, which will later be compared to MultiMag solutions. In addition, recovery, leaching and oxide reduction technologies for materials like neodymium used in permanent magnets, have been further developed to ensure effective recyclability of REE materials.
MultiMag project supports the development of advanced materials and their sustainable use in products and processes. In addition, raw materials secure value chain in Europe is a high priority for MultiMag. Project partners are key players in the field of advanced materials, necessary for electric motors. There are only a few companies in Europe working with magnetic materials, and cooperation between these companies and organizations utilizing these materials is essential to meet the requirements of the applications. Joint activities can lead to results which are challenging to reach alone. The companies involved in the project have plans for commercialization these materials by up scaling the production.
Circulating REE materials back to use is also an important part of MultiMag. The achieved results related to recovery and purity of recycled material are promising. Not only do they support sustainability targets, but they also provide business opportunities for the companies involved.
In addition, MultiMag aims to create competitive edge for industrial partners and the European industry as a whole by increasing the cross-sectorial cooperation along the value chain and by promoting the adoption of key digital and enabling technologies in industrial value chains.
Overall, whole MultiMag approach is tuned to pave the way for carbon neutrality and climate change mitigation by creating products and processes which reduce greenhouse gas emissions.
Circulating REE materials back to use is also an important part of MultiMag. The achieved results related to recovery and purity of recycled material are promising. Not only do they support sustainability targets, but they also provide business opportunities for the companies involved.
In addition, MultiMag aims to create competitive edge for industrial partners and the European industry as a whole by increasing the cross-sectorial cooperation along the value chain and by promoting the adoption of key digital and enabling technologies in industrial value chains.
Overall, whole MultiMag approach is tuned to pave the way for carbon neutrality and climate change mitigation by creating products and processes which reduce greenhouse gas emissions.