Periodic Reporting for period 1 - HEFT (Novel concept of a low cost, high power density and highly efficient recyclable motor for next generation mass produced electric vehicles)
Periodo di rendicontazione: 2022-12-01 al 2024-05-31
The general objective of HEFT is to develop and test two variants of lower cost, higher efficiency and power density permanent magnet eMotors for mass produced cars and vans.
Two main technical objectives:
[MO1] Development of lower cost, higher efficiency and power density electric motors for mass produced cars and vans. HEFT innovations:
[MO2] Development of a resilient long-term strategy to face rare earth CRM (Critical Raw Material) supply chain possible issues. In HEFT project, high saving rates (>60%) of primary rare earth CRM will be achieved.
Two main technical objectives:
[MO1] Development of lower cost, higher efficiency and power density electric motors for mass produced cars and vans. HEFT innovations:
[MO2] Development of a resilient long-term strategy to face rare earth CRM (Critical Raw Material) supply chain possible issues. In HEFT project, high saving rates (>60%) of primary rare earth CRM will be achieved.
WP1
During the M1-M8 period the WP1 has been developed and finished. All the deliverables have been submitted (D1.1 D1.2 D1.3 and D1.4).
Market analysis and roadmap for the next 5-10 years have been done, based on that information the motor specifications for A+B and C+D segments have been presented
WP2
T2.1 Improve Ce based magnets and recycled magnets
During M1-M18 Magneti Ljubljana has been working on material development of Ce magnets and recycled magnets for a magnetic grade of N38H for A+B segment motor.
T2.2 Circular strategy to recover magnets
For the magnet encapsulation material, Sumikon® EME M300 was selected. The compound is processable through a molding process and capable of fixating the magnets to withstand high rotating speeds and temperatures. Besides enabling a solid fixation, the end-of-life magnets are required to be removed under a mechanical or thermal process in order to meet the requirements for the reuse of rare earth permanent magnets.
A new cost-effective full process to recover magnets from End-of-Life (EoL) rotors, which includes demagnetize, eliminate epoxy from magnets when needed, cleaning and quality testing and selection. Repetitive extraction tests have been applied for two rotor stacks (with the magnets moulded using this special epoxy). These tests validate the REE recycled route regarding to the direct reusing of the magnets in a second generation motor with reused magnets.
T2.3 Materials for housing and cooling
The material development for the eMotor’s housing and cooling system is listed under WP2 – task 2.3. For the housing material, a moldable composite was selected in order to meet with the requirements stated in the project proposal (e.g. weight reduction compared to traditional materials and structural behavior). Vyncolit® X6580 phenolic mineral and glass fiber-filled molding compound was further developed for this application.
T2.4 Materials to 800 V insulation systems
In T2.4 an initial assessment of the insulation voltage stress was conducted in compliance with IEC 60034-18-41 standards. Four slot molding resins produced by SUMIBE were evaluated based on their electrical properties. Two resins were selected for further testing due to their favorable electrical and thermal properties. The decline of PDIV was negligible, indicating that the selected materials exhibited satisfactory electrical properties under the testing conditions.
WP3
During the M1-M8 period the WP3 Task 3.1 and T3.2 have been developed and finished. D3.1 has been uploaded.
T3.1 Modular, high-efficient and cost-oriented 800V powertrain architecture
A modular, high-efficient and cost oriented 800 V powertrain architecture was defined.
On the other hand, a simulation model to analyze high dv/dt effects that generate SiC devices have been proposed in this study. Finally, advanced shared cooling system for the powertrain has been analysed and simulated.
T3.2
In this task, a SiC-based drive control to reduce powertrain losses and improve EV range has been modeled and designed using Matlab/Simulink simulation tool. The simulation model develoepd is able to generate automatic code directly, which will be used in the validation tasks in WP5.
T3.3
This task a optimal powertrain virtual validation is going to be carried out. Up to now a planning of the different models needs to carry out this validation has been done and some of the models have been developed.
WP4
During the M1-M18 period, the following activities have been developed within WP4:
A+B segment motor:
T4.1:
-- Full eMotor design was proposed based on defined requirements, KPIs, manufacturing restrictions and geometrical constraints.
T4.2:
- Cooling system concept defined.
- Rotor cooling defined.
- Stator cooling definition in progress.
T4.3
- Manufacturing processes for eMotor production defined.
- Stator manufacturing processes defined and detailed for continuous winding production.
C+D+E segment motor:
T4.1:
- Preliminary eMotor design was proposed based on defined requirements, KPIs, manufacturing restrictions and geometrical constraints.
T4.2:
- Cooling system concept defined.
WP5
This WP will start in M19.
WP6: New Circular Economy model
Task 6.1: Recyclability and resource efficiency of the new eMotors
In this task, we have estimated the potential coverage of future EU demand for rare earth magnets through the recycling of PMs from end-of-life EVs.
The first draft of the results shows the establishment of an EV PM recycling chain within the EU contributes an estimated 29-69% to the overall demand between 2025 and 2030.
Task 6.2: Criticality of the supply chain
In this task we have assessed the criticality of the supply risk associated with REEs and other critical metals used in PMs of EVs.The first draft of the results shows that among the critical metals used in PM production, Dysprosium has the highest probability of supply disruption and poses the greatest risk to the product system.
Task 6.3: Life cycle assessment
The goal of the LCA is to evaluate the environmental impact of four types of magnets that will be developed in HEFT project. Mining and production of raw materials and magnet manufacturing for C2 magnet are already modeled in Gabi. Raw materials production and the powder preparation are the major contributors to the environmental impact.
Task 6.4: Life cycle costing
As part of this task, a master thesis recently conducted a Cost-Benefit Analysis (CBA) to assess permanent magnet motors to be developed in HEFT project.The results indicate that recycling and reuse scenarios have the potential to be economically profitable for PM industry manufacturers.
Task 6.5: New circular scenarios
This task involves integrating the findings from the previous tasks to develop new circular economy scenarios. This work will be conducted in the future.
During the M1-M8 period the WP1 has been developed and finished. All the deliverables have been submitted (D1.1 D1.2 D1.3 and D1.4).
Market analysis and roadmap for the next 5-10 years have been done, based on that information the motor specifications for A+B and C+D segments have been presented
WP2
T2.1 Improve Ce based magnets and recycled magnets
During M1-M18 Magneti Ljubljana has been working on material development of Ce magnets and recycled magnets for a magnetic grade of N38H for A+B segment motor.
T2.2 Circular strategy to recover magnets
For the magnet encapsulation material, Sumikon® EME M300 was selected. The compound is processable through a molding process and capable of fixating the magnets to withstand high rotating speeds and temperatures. Besides enabling a solid fixation, the end-of-life magnets are required to be removed under a mechanical or thermal process in order to meet the requirements for the reuse of rare earth permanent magnets.
A new cost-effective full process to recover magnets from End-of-Life (EoL) rotors, which includes demagnetize, eliminate epoxy from magnets when needed, cleaning and quality testing and selection. Repetitive extraction tests have been applied for two rotor stacks (with the magnets moulded using this special epoxy). These tests validate the REE recycled route regarding to the direct reusing of the magnets in a second generation motor with reused magnets.
T2.3 Materials for housing and cooling
The material development for the eMotor’s housing and cooling system is listed under WP2 – task 2.3. For the housing material, a moldable composite was selected in order to meet with the requirements stated in the project proposal (e.g. weight reduction compared to traditional materials and structural behavior). Vyncolit® X6580 phenolic mineral and glass fiber-filled molding compound was further developed for this application.
T2.4 Materials to 800 V insulation systems
In T2.4 an initial assessment of the insulation voltage stress was conducted in compliance with IEC 60034-18-41 standards. Four slot molding resins produced by SUMIBE were evaluated based on their electrical properties. Two resins were selected for further testing due to their favorable electrical and thermal properties. The decline of PDIV was negligible, indicating that the selected materials exhibited satisfactory electrical properties under the testing conditions.
WP3
During the M1-M8 period the WP3 Task 3.1 and T3.2 have been developed and finished. D3.1 has been uploaded.
T3.1 Modular, high-efficient and cost-oriented 800V powertrain architecture
A modular, high-efficient and cost oriented 800 V powertrain architecture was defined.
On the other hand, a simulation model to analyze high dv/dt effects that generate SiC devices have been proposed in this study. Finally, advanced shared cooling system for the powertrain has been analysed and simulated.
T3.2
In this task, a SiC-based drive control to reduce powertrain losses and improve EV range has been modeled and designed using Matlab/Simulink simulation tool. The simulation model develoepd is able to generate automatic code directly, which will be used in the validation tasks in WP5.
T3.3
This task a optimal powertrain virtual validation is going to be carried out. Up to now a planning of the different models needs to carry out this validation has been done and some of the models have been developed.
WP4
During the M1-M18 period, the following activities have been developed within WP4:
A+B segment motor:
T4.1:
-- Full eMotor design was proposed based on defined requirements, KPIs, manufacturing restrictions and geometrical constraints.
T4.2:
- Cooling system concept defined.
- Rotor cooling defined.
- Stator cooling definition in progress.
T4.3
- Manufacturing processes for eMotor production defined.
- Stator manufacturing processes defined and detailed for continuous winding production.
C+D+E segment motor:
T4.1:
- Preliminary eMotor design was proposed based on defined requirements, KPIs, manufacturing restrictions and geometrical constraints.
T4.2:
- Cooling system concept defined.
WP5
This WP will start in M19.
WP6: New Circular Economy model
Task 6.1: Recyclability and resource efficiency of the new eMotors
In this task, we have estimated the potential coverage of future EU demand for rare earth magnets through the recycling of PMs from end-of-life EVs.
The first draft of the results shows the establishment of an EV PM recycling chain within the EU contributes an estimated 29-69% to the overall demand between 2025 and 2030.
Task 6.2: Criticality of the supply chain
In this task we have assessed the criticality of the supply risk associated with REEs and other critical metals used in PMs of EVs.The first draft of the results shows that among the critical metals used in PM production, Dysprosium has the highest probability of supply disruption and poses the greatest risk to the product system.
Task 6.3: Life cycle assessment
The goal of the LCA is to evaluate the environmental impact of four types of magnets that will be developed in HEFT project. Mining and production of raw materials and magnet manufacturing for C2 magnet are already modeled in Gabi. Raw materials production and the powder preparation are the major contributors to the environmental impact.
Task 6.4: Life cycle costing
As part of this task, a master thesis recently conducted a Cost-Benefit Analysis (CBA) to assess permanent magnet motors to be developed in HEFT project.The results indicate that recycling and reuse scenarios have the potential to be economically profitable for PM industry manufacturers.
Task 6.5: New circular scenarios
This task involves integrating the findings from the previous tasks to develop new circular economy scenarios. This work will be conducted in the future.
Considering this innovation activities, HEFT concept will be built around a series of technological challenges:
1. New magnets with less REE content (NdCeFeB magnets or Dy free…)
2. Recycled NdFeB magnets
3. Improved rotor cooling system
4. Multibarrier rotor topology with alternative magnets
5. High strength magnet fixation compound
6. Composite structural motor housing
7. Advance stator cooling system
8. Jet cooling on motor end-windings
9. High voltage with an advance insulation system
10.Wave winding technology
11. eMotor improvements due to an optimized use of SiC inverters
12. Advanced Digital twin platform
13. New business models for eMotors in a circular economy and new opportunities in the eMotors value chain
1. New magnets with less REE content (NdCeFeB magnets or Dy free…)
2. Recycled NdFeB magnets
3. Improved rotor cooling system
4. Multibarrier rotor topology with alternative magnets
5. High strength magnet fixation compound
6. Composite structural motor housing
7. Advance stator cooling system
8. Jet cooling on motor end-windings
9. High voltage with an advance insulation system
10.Wave winding technology
11. eMotor improvements due to an optimized use of SiC inverters
12. Advanced Digital twin platform
13. New business models for eMotors in a circular economy and new opportunities in the eMotors value chain