Periodic Reporting for period 1 - MAXIMA (Modular AXIal flux Motor for Automotive)
Période du rapport: 2023-02-01 au 2024-07-31
Widespread electrification in automotive will necessarily require the manufacturing of low-cost components to ensure that vehicles remain accessible to the greatest number of people. In a context of sustainable development, these components must also minimize environmental impact and reduce the high risks associated with their supply chain. The rotating Electrical Machine (EM), a critical component of the powertrain, is also subject to these constraints. In 2020, most EMs on the market were Permanent Magnet (PM) synchronous machines. These EMs were primarily designed to meet manufacturing cost and performance requirements, often without fully accounting for their environmental impact throughout their life cycle, including key factors such as energy efficiency and recyclability. Moreover, the use of Critical Raw Materials (CRM) should be minimized throughout the entire life cycle of EMs. This approach is no longer optional: future EMs must incorporate an environmental impact assessment from the earliest stages of design, considering every phase of the life cycle assessment (LCA)—from raw material extraction to manufacturing, operation, and dismantling/recycling—while limiting CRM usage. Despite this, most electric vehicles still rely on radial flux EMs. Among these, PM radial flux EMs have been the preferred choice for most car manufacturers and suppliers as traction motors. However, an in-depth analysis of axial flux EM technology reveals significant potential for further enhancing the performance of electric powertrains. In addition to continuing efforts to improve torque/power density and efficiency, the main challenges facing PM axial flux EMs are the scarcity of rare earth PM and the high mass production costs, which remain too steep to be viable for the core automotive market (50kW-120kW). The ambition of MAXIMA is to design and develop a low-cost modular PM axial flux EM for the core automotive market, delivering improved performance while incorporating strategies that minimize the use of CRMs and reduce environmental impact. T To enhance performance, an advanced multiphysics design procedure incorporating innovative thermal management concepts will be developed. Additionally, a Digital Twin (DT) – a virtual replica of the EM – will be created to develop an optimal control strategy, enabling the EM to operate at its maximum potential. To reduce costs, the EM will be designed simultaneously with its manufacturing process flow which will be optimized for mass production by considering a modular concept design. The EM’s end of life will also be considered, especially the recycling of the PM made from CRM. To minimize environmental impact, each solution will be evaluated through a LCA. At the conclusion of the MAXIMA project, prototypes will be produced for testing, assessment, and validation of the new concepts developed. These include the modular design of the EM, optimal control strategies based on the DT, and the manufacturing and recycling process flows.
The types of electric vehicles and their typical duty cycles relevant to the core market have been selected by the OEM. Specifications and requirements for both organic aspects (such as volumes and interfaces) and functional aspects (such as cycles and reference vehicles) have been defined, complementing the specifications outlined in the EU call. An in-depth analysis of a 2020 market reference electrical machine (including its specifications and performance) was conducted to serve as a benchmark for the axial flux EM design within the MAXIMA project.
Based on these specifications, preliminary analyses of the electromagnetic, thermal, and mechanical aspects, considering manufacturing requirements, have led to the selection of two geometries for the axial flux machine. Both geometries are currently undergoing optimization from electromagnetic, thermal, and mechanical perspectives. The design is being refined to cover the targeted power range with a limited number of parts, with a strong emphasis on manufacturing considerations. This includes chain dimension and tolerance analysis for each geometry to assess assembly constraints. Concurrently, integration proposals with the power converter have been developed for both solutions to optimize thermal behavior. Vehicle simulations using the WLTP Driving Cycle are now underway to compare the different solutions at the system level.
The LCA of the EM as well as it manufacturing process has started to be addressed. Data about processes and materials have been collected. Preliminary results have been obtained enabling to compare different solutions proposed during the design process of the EM as well as its manufacturing process.
The end-of-life considerations include a focus on recycling rare earth PM. Initial recycling trials have been conducted, exploring a short recycling route for these magnets. Additionally, studies have begun to design PM with reduced heavy rare earth content while ensuring they meet the magnetic characteristics required for the MAXIMA project.
Based on these specifications, preliminary analyses of the electromagnetic, thermal, and mechanical aspects, considering manufacturing requirements, have led to the selection of two geometries for the axial flux machine. Both geometries are currently undergoing optimization from electromagnetic, thermal, and mechanical perspectives. The design is being refined to cover the targeted power range with a limited number of parts, with a strong emphasis on manufacturing considerations. This includes chain dimension and tolerance analysis for each geometry to assess assembly constraints. Concurrently, integration proposals with the power converter have been developed for both solutions to optimize thermal behavior. Vehicle simulations using the WLTP Driving Cycle are now underway to compare the different solutions at the system level.
The LCA of the EM as well as it manufacturing process has started to be addressed. Data about processes and materials have been collected. Preliminary results have been obtained enabling to compare different solutions proposed during the design process of the EM as well as its manufacturing process.
The end-of-life considerations include a focus on recycling rare earth PM. Initial recycling trials have been conducted, exploring a short recycling route for these magnets. Additionally, studies have begun to design PM with reduced heavy rare earth content while ensuring they meet the magnetic characteristics required for the MAXIMA project.
The aim of the MAXIMA project is to design electric motors that are lower in cost, and higher in efficiency and power density for mass-produced cars and vans. The project focuses on enabling easy dismantling and recyclability while reducing the use of rare resources by developing or applying alternative materials and advanced configurations. To achieve this objective, a design methodology for the axial flux machine is employed that integrates considerations for manufacturing and recycling to control both cost and environmental impact. Performance and environmental impact are compared to a reference machine available on the market in 2020. Additionally, studies are conducted to design specialized PM for axial flux machines that minimize the use of CRMs, particularly heavy rare earth materials.
In the MAXIMA project, the role of LCA has been emphasized during the design of the electrical machine, as well as its manufacturing and recycling process flow. The project focuses on improving motor design and development processes by incorporating a comprehensive product LCA within a circular economy framework, aiming to reduce total energy and resource consumption.
The methodology to evaluate the environmental impact of a design of an electrical machine and its manufacturing process is now operational. This methodology is integrated into both the design and manufacturing procedures of the electrical machine. Each new solution is assessed within the design process, ensuring that environmental impact is a key factor in decision-making.
In the MAXIMA project, the role of LCA has been emphasized during the design of the electrical machine, as well as its manufacturing and recycling process flow. The project focuses on improving motor design and development processes by incorporating a comprehensive product LCA within a circular economy framework, aiming to reduce total energy and resource consumption.
The methodology to evaluate the environmental impact of a design of an electrical machine and its manufacturing process is now operational. This methodology is integrated into both the design and manufacturing procedures of the electrical machine. Each new solution is assessed within the design process, ensuring that environmental impact is a key factor in decision-making.