Innovative e-motor technologies covering e-axles and e-corners vehicle architectures for high-efficient and sustainable e-mobility

Projektinformationen

EM-TECH

ID Finanzhilfevereinbarung: 101096083

DOI

10.3030/101096083

Projekt abgeschlossen

EK-Unterschriftsdatum 14 Dezember 2022

Startdatum 1 Januar 2023

Enddatum 31 Dezember 2025

Finanziert unter

• Climate, Energy and Mobility

Gesamtkosten

€ 3 834 550,00

EU-Beitrag

€ 3 834 550,00

Koordiniert durch

AVL LIST GMBH
Austria

Periodic Reporting for period 1 - EM-TECH (Innovative e-motor technologies covering e-axles and e-corners vehicle architectures for high-efficient and sustainable e-mobility)

Berichtszeitraum: 2023-01-01 bis 2024-06-30

Zusammenfassung vom Kontext und den Gesamtzielen des Projekts

EM-TECH brings together 10 participants from industry and academia to develop novel solutions to push the boundaries of electric machine technology for automotive traction, through:
i) innovative direct and active cooling designs;
ii) virtual sensing functionalities for the high-fidelity real-time estimation of the operating condition of the machine;
iii) enhanced machine control, bringing reduced design and operating conservativeness enabled by ii);
iv) electric gearing to provide enhanced operational flexibility and energy efficiency;
v) digital twin based optimisation, embedding systematic consideration of Life Cycle Analysis and Life Cycle Costing aspects since the early design stages; and
vi) adoption of recycled permanent magnets and circularity solutions.
The proposed innovations will be implemented in new series of radial flux direct drive in-wheel motors characterised by so far unexplored levels of torque density (>150 Nm/litre, >50 Nm/kg), and on-board single stator double rotor type ironless axial flux machines providing power density and specific power levels in excess of 30 kW/litre and 10 kW/kg. The solutions will address both passenger car and van applications (continuous power levels of 50 kW - 120 kW), providing competitive costs (<6 Euro/kg for a production of 100000 units/year), and leading to significant reduction of motor energy loss during real vehicle operation (>25%), and to >60% decrease of the rare earth content, including implementation of magnet recycling solutions. EM-TECH obtained the support of several car makers (AUDI and Changan UK), which will strengthen the exploitation strategy. EM-TECH will further directly contribute to the relevant European Destination and KSO C and A, by supporting the establishment of a European leadership in the sector of key digital, enabling and emerging technologies, and the development of the respective value chains.

Arbeit, die ab Beginn des Projekts bis zum Ende des durch den Bericht erfassten Berichtszeitraums geleistet wurde, und die wichtigsten bis dahin erzielten Ergebnisse

- Definition of the "baseline" EoL-scenario for e-machines in the automotive sector according to the legal framework defined in the ELV-Directive and the recycling procedures prcaticed in Europe for the correspondent material fraction recovery according to the state-of-the-art.
- Determination of boottlenecks in the recycling of permanent amgents in the "baseline" EoL-scenario
- Determination of real recycling rate of materials considering primary and secondary production, import and export of goods/waste, import and export of scrap.
- Incorporation of the data in a LCA/LCC
- Circular design soltuion for the e-machines considering parameters as the material selection, use of composites/assembly of different materials and structural design.

Fortschritte, die über den aktuellen Stand der Technik hinausgehen und voraussichtliche potenzielle Auswirkungen (einschließlich der bis dato erzielten sozioökonomischen Auswirkungen und weiter gefassten gesellschaftlichen Auswirkungen des Projekts)

- Determination of dismantling/dissassembly costs to enable an economic recycling of the critical raw materials while avoiding an "over-sorting" of material types that eventually can be co-processed in the recycling industry according to the stae-of-the art