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Novel concept of a low cost, high power density and highly efficient recyclable motor for next generation mass produced electric vehicles

Project description

DEENESFRITPL

Novel synchronous motors for electric vehicles

Climate change has created an increased need for innovation in various sectors, including the automotive industry. Many corporations are striving to fulfil this need by developing and producing electric cars. However, the production process remains inefficient and environmentally harmful. The EU-funded HEFT project will reverse this trend by introducing a revolutionary synchronous motor for electric cars, which will be recyclable, cost-efficient and require fewer materials while producing fewer emissions and creating novel European circular economies. HEFT is a research project that brings together the expertise of universities, research centers and companies in electric motors, advanced materials and circularity, from basic research to the development and testing of new materials and components.

Objective

HEFT considers that an energy efficient rare-earth synchronous motor is the best option for next generation high-power primary axle traction EVs and proposes a set of innovation challenges on electric synchronous motor configuration based on SiC inverters (direct cooling of rotor and stator, advance insulation for high voltage, multibarrier rotor topology, wave windings) and advanced materials (advanced GBD magnets, epoxy for magnet fixation, composite for motor housing, insulation resin).
These innovations will result in a high-efficient and low-cost solution that will be validated on 2 motor topologies, which compared to two main reference automotive IPM commercial motors in Europe (VW ID.3 and FIAT500) will lead to next impacts: >800V, 20% reduction losses, >7 KW/kg and 42kW/l power density, 28% cheaper, 50-66% material savings, including 60% reduction of REE content and >80% REE recyclability rate.
As this solution is still dependent on REE from China, HEFT will be aligned with the ERMA action plan towards a circular economy market of rare earth permanent magnets and suggests: one alternative magnet route (Ce based) and two REE recycled routes together with policies promotion towards the foundation of a European rare earths industry, capable of delivering 20% of EU demand by 2030.
HEFT plans 8 WPs to implement these concepts, where 5 research partners will be essential for developing innovative ideas around the design-to-x approach, while strong companies (GKN, MAGNETI, VYNCOLIT) will ensure that HEFT results have a clear market orientation and fulfil the industry needs.
HEFT plans to organise OEM workshops to ensure wide adoption of HEFT solutions, but also with policymakers to promote regulations towards the EU circular market that would help maintaining the leadership of EU companies, while increasing their competitiveness and job opportunities linked to the new circular business models.

Fields of science

Programme(s)

Topic(s)

Call for proposal

HORIZON-CL5-2022-D5-01

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Funding Scheme

RIA - Research and Innovation action

Coordinator

MONDRAGON GOI ESKOLA POLITEKNIKOA JOSE MARIA ARIZMENDIARRIETA S COOP
Net EU contribution
€ 656 126,25
Address
Loramendi 4
20500 Arrasate
Spain

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Region
Noreste País Vasco Gipuzkoa
Activity type
Higher or Secondary Education Establishments
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Other funding
€ 0,00

Participants (6)

Partners (2)

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Last update: 28 November 2022
Record number: 243265

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European Union, 2023