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Rare Earth Free e-Drives featuring low cost manufacturing

Objective

The ReFreeDrive project is focused on contributing to avoid the use of rare earth magnets through the development of a next generation of electric drivetrains, ensuring the industrial feasibility for mass production while focusing on the low cost of the manufacturing technologies.
This proposal intends to study and develop simultaneously two solutions for the power traction system of electrical vehicles. Both solutions are brushless AC electrical machines: induction machine with fabricated and copper die-cast rotor (IM) and synchronous reluctance (SynRel) machine. Through their configurations these machines not only are rare-earth magnet free, but also share common features that can be exploited during the design step, as well in the manufacturing process. These common features lead to a complex synergy between the two technologies, which justify the development of different topologies of electric machines in just one project.
The design of the ReFreeDrive motors will take as a premise the reduction of use of materials, as more than half of the final price is formed by raw materials cost. Also, a minimization of manufacturing costs will be ensured by an early involvement of manufacturers, from the design stage. ReFreeDrive motor topologies have good room for cost reduction by off-setting permanent magnet use. However, it is not feasible to change the commodity prices for copper and steel. Therefore, one of the key avenues for cost reduction is the reduction of size through different techniques (outer rotor, higher rotational speed, compact winding…). An optimized use of copper on the project provides technical design with a higher efficiency due to lower losses regards other alternatives, and more efficient heat management.
Beyond the motor design, ReFreeDrive also consider an integrated design of the power train that allows the optimization of the electric connections, the cooling systems and the housing.

Field of science

  • /natural sciences/mathematics/pure mathematics/topology

Call for proposal

H2020-GV-2017
See other projects for this call

Funding Scheme

RIA - Research and Innovation action

Coordinator

FUNDACION CIDAUT
Address
Plaza Vicente Aleixandre Campos 2 Pq Tecnologico De Boecillo 209
47151 Valladolid
Spain
Activity type
Research Organisations
EU contribution
€ 448 125

Participants (12)

EUROPEAN COPPER INSTITUTE
United Kingdom
EU contribution
€ 97 950
Address
Grovelands Business Centre 5 Boundary Way
HP2 7TE Hemel Hempstead
Activity type
Other
MOTOR DESIGN LTD
United Kingdom
EU contribution
€ 593 325
Address
5 Edison Court Wrexham Technology Park
LL13 7YT Wrexham
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
UNIVERSITA DEGLI STUDI DELL'AQUILA
Italy
EU contribution
€ 788 750
Address
Piazza Santa Margherita 2
67100 L Aquila
Activity type
Higher or Secondary Education Establishments
IFP Energies nouvelles
France
EU contribution
€ 867 736,25
Address
Avenue De Bois Preau 1 & 4
92500 Rueil Malmaison
Activity type
Research Organisations
RINA CONSULTING - CENTRO SVILUPPO MATERIALI SPA
Italy
EU contribution
€ 363 770
Address
Via Di Castel Romano 100
00128 Roma
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
TECNOMATIC SPA
Italy
EU contribution
€ 431 250
Address
Via Delle Caserme 85
65127 Pescara
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
MAVEL SRL
Italy
EU contribution
€ 451 850
Address
Via Gressoney 29
11026 Pont-saint-martin
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
METALLGIESSEREI BREUCKMANN GMBH & CO KG
Germany
EU contribution
€ 245 000
Address
Dieselstrasse 28
42579 Heiligenhaus
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
AURUBIS BELGIUM
Belgium
EU contribution
€ 72 625
Address
Rue Du Marais 31
1000 Brussels
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
R13 TECHNOLOGY SRL
Italy
EU contribution
€ 460 000
Address
Via Giovanni Gronchi 18 Localita Campo Di Pile
67100 L'aquila
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
PRIVE' SRL
Italy
EU contribution
€ 705 625
Address
Strada Del Colle 1/A
06132 Perugia
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
JAGUAR LAND ROVER LIMITED
United Kingdom
EU contribution
€ 473 125
Address
Abbey Road Whitley
CV3 4LF Coventry
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)