Major steps have been taken towards the key objectives. First, the manufacturing of the 50-kW electric traction motor prototypes has begun. This task has necessitated a balance among the competing objectives of reducing and recycling rare earth permanent magnets (PMs), enhancing energy efficiency, and minimizing the motors' physical size. Optimization of the 120-kW motor prototypes towards 7 kW/kg and 20% reduction of losses is in good progress as well. The motor design tasks have engaged multiple project partners in conducting multi-physics computations and analyses, thorough material and manufacturing assessments, and intricate computer-aided integration of various motor components, including both active and supporting elements, as well as the direct liquid cooling of the windings.
To date, the key technical accomplishments in ecodesign and sustainability include the comprehensive life cycle analysis (LCA) and life cycle costing (LCC) of selected VOLTCAR motor designs. The findings have provided insights into how decisions at various stages affect overall performance, cost, and sustainability, leading to significant enhancements in the designs of the 120-kW motors from one version to the next. A motor analysis application has been developed, too. With this application, we have been able to benchmark various commercial designs very efficiently and reliably and compare those against our own VOLTCAR designs. Last, to improve the circularity of rare earth PMs and minimize the reliance on virgin materials, we have created initial samples of encapsulated magnets for easy removal and subsequent reuse in, e.g. another application.
The principles of the VOLTCAR digital platform have been established, and the digital threads that make up the entity have been specified. Digital threads encompass the VOLTCAR electric traction motor and other powertrain components and vehicle dynamics. The platform and its components are being actively developed to explore the intricate connections between the state of manufacturing tools, part quality, and ultimately, motor lifespan. Additionally, it aims to enable, e.g. virtual inspections of motor conditions.
Since the VOLTCAR prototypes are on their way, so far, testing and validation activities have comprised of planning the experiments (subassemblies, motor back-to-back, and complete motor with gear) and also, implementing initial test setups to validate the feasibility of our XiL simulation concepts.
