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)
Okres sprawozdawczy: 2023-01-01 do 2024-06-30
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.
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.
- 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.
- 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.
- 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