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Design, manufacturing, and validation of ecocycle electric traction motor

Periodic Reporting for period 1 - VOLTCAR (Design, manufacturing, and validation of ecocycle electric traction motor)

Reporting period: 2023-02-01 to 2024-07-31

Recent developments have resulted in cleaner and more efficient options for electric transportation. Whilst related technologies have evolved over a couple of generations, certain challenges continue to persist.
On the part of the electric traction motors the specific issues include 1) how to reduce the dependency on the critical and strategic materials while simultaneously improving the most important performance criteria; 2) how to maintain the leading position of European car manufacturers also in the mass manufacturing segments and consequently, enhance the competitiveness of whole Europe; 3) how to increase the overall attractiveness of the electric vehicles.
In response to the identified challenges, Horizon Europe project “Design, manufacturing, and validation of ecocycle electric traction motor”, VOLTCAR, aims at developing a next generation electric traction motor that meets the strictest performance requirements (power density, energy efficiency), sustainability criteria (recyclability, circularity and low use of rare resources and copper) and the expectations of the automotive sector (cost, reliability, integrability). This major goal is supported by introducing digital design and optimization methodologies that can assess the life cycle costs, energy consumption, and carbon footprint in the early phase, guiding the outcomes towards maximized sustainability with reduced use of rare materials and efficient recycling and repurposing patterns. The 50-kW and 120-kW VOLTCAR motor prototypes and related technologies are experimented according to relevant standards, presenting an X-in-the-loop (XiL) experimentation environment. With this initiative, VOLTCAR aims to provide the automotive industry with competitive solutions, foster the creation of green jobs in Europe, and enhance the appeal of electromobility for everyone.
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.
VOLTCAR is proposing state-of-the-art electric traction motor designs that fulfil the strictest requirements, with reduced amount of rare earth PMs. All research and development steps are conducted with the potential for larger-scale application in mind. We aim to leverage the best practices in mass manufacturing of electric machines without adding many extra processing steps. By these means, we aim at ensuring the further exploitation of the VOLTCAR results.
The LCA and LCC calculations of several VOLTCAR motor designs have already been performed and these yield guidelines for the motor developments. Also, the encapsulation of the PMs for removal intact have been progressed. The data produced can contribute to the developments of the digital threading and digital twinning, too. Regulations and expectations on the sustainability are tightening and to be successful one cannot omit these aspects.
Modeling and simulation are at the heart of modern product development and manufacturing processes. VOLTCAR aims to elevate the present state-of-the-art by introduction of a digital platform that would allow assessing the motor’s performance during its lifetime. The VOLTCAR platform and the first use cases are under intensive development and planned to be demonstrated during the second half of the project.
Last, to prove the benefits of the VOLTCAR outcomes, practical experiments need to be carried out. The measurements of the VOLTCAR prototypes are scheduled for the second half of the project. The whole purpose of the extensive testing campaign is to show how we reached the set targets but also to provide material for the communication, dissemination, and exploitation of the results and hopefully, for promoting and advancing clean electrification.
KUL NVH workflow for motor noise prediction
3D model picture of the VOLTCAR motor prototype
VOLTCAR Digital Twin Platform
Stamping tool design for the VOLTCAR rotor as envisaged by Hidria