EV emotors without Rare Earth Materials
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1 EV emotors without Rare Earth Materials James Widmer
2 Centre for Advanced Research into Power Electronics, Drives and Machines for: Transport (Air, Land, Sea) New and Renewable Energy (Small / Large) High Volume Products (Low Cost, Efficiency)
3 People and Facilities Personnel: 14 academics, 25 Research Staff, 50 PhD students, dedicated technicians and administration Test equipment: Dynamometers (up to 500kW and up to 100,000 revs/min), State of art instrumentation, Environmental chambers Simulation hardware and software: Matlab, Saber, Finite element electromagnetic, mechanical and thermal platforms (JMAG, Infolytica, Ansys) Manufacturing equipment: Wire erosion machine, Cnc milling machines, Balancing, magnetising and winding machines
4 Partnerships Aerospace: Airbus, BAE Systems, Goodrich, United Technologies, QinetiQ Automotive: Renault, Daimler, Jaguar- Landrover, Volvo, Leyland Trucks, Prodrive, Protean, Avid, Sevcon, Zytek Domestic: Dyson, Black and Decker Industrial: Control Techniques Generation: Turbo-Power Systems, Converteam, Siemens, Cummins Materials: Höganӓs, Tata Steel
5 Contents Why are emotors Important? EV emotor Landscape Eliminating Rare Earth Materials Case-Study: Rare Earth Free Motors Conclusions
6 Contents Why are emotors Important? EV emotor Landscape Eliminating Rare Earth Materials Case-Study: Rare Earth Free Motors Conclusions
7 Motor Facts (source IEA) 45% of all electrical energy to motors 7000 TWh/year 6040 Mt CO2/year >99% of all electrical energy from electrical generators backwards motors 250M electric motors sold across EU in 2010 (EU) 12M Electric Vehicles per year by 2030 requiring large, volume produced electric motors (Credit Suisse)
8 Contents Why are emotors Important? EV emotor Landscape Eliminating Rare Earth Materials Case-Study: Rare Earth Free Motors Conclusions
9 EV emotor Landscape INDUCTION MOTORS RARE EARTH MAGNET MOTORS The traditional choice The class leader WOUND ROTOR MOTORS RELUCTANCE MOTORS Large generators Difficult and noisy?
10 So how are rare earth materials used in emotors?
11 Neodymium Magnets 3 mm NdFeB magnet 13 Amps through 200 turns of copper +
12 Dysprosium Doping (Brown et al, JoP, 2014)
13 EV emotor Landscape INDUCTION MOTORS RARE EARTH MAGNET MOTORS The traditional choice The class leader WOUND ROTOR MOTORS RELUCTANCE MOTORS Large generators Difficult and noisy?
14 USD ($) Rare Earth Magnet Problems Materials Cost 30kW Traction Motors (NdFeB - $132/kg) ,6 71% NdFeB Copper ,38 Steel ,53 49,1 31,03 25,05 23,41 Interior Permanent Magnet Motor Switched Reluctance Motor Induction Motor (Brown (Dorrell et et al, al, IEEE, JoP, 2010) 2014)
15 Rare Earth Magnet Problems Normalised GHG Emissions from Life Cycle Assessment (LCA) 1 0,5 0 NdFeB Magnet Copper Aluminium Steel Polypropylene (Unattributed )
16 EV emotor Landscape INDUCTION MOTORS RARE EARTH MAGNET MOTORS The traditional choice The class leader WOUND ROTOR MOTORS RELUCTANCE MOTORS Large generators Difficult and noisy?
17 Rare Earths & Motor Size Application Power Magnet Mass Metric 6MW ~2T ~3kW/kg 80kW ~2kg ~40kW/kg 200W ~2g ~100kW/kg
18 Contents Why are emotors Important? EV emotor Landscape Eliminating Rare Earth Materials Case-Study: Rare Earth Free Motors Conclusions
19 Reduced NdFeB and Dy Hybrid Magnet / Reluctance Motors Improved motor cooling Reduce dependence on Dy Reduced Dysprosium content E.g. Hitachi metals diffusion process (BMW i3)
20 Substitute NdFeB and Dy SmCo Excellent at high temperatures Same issues as NdFeB (Kim et al, IEE IA, 2013) Ferrite magnets Low cost Low performance Demagnetisation risk (MotorBrain FP7 Project)
21 Rare Earth Free Reluctance motors: Synchronous Reluctance Motors Switched Reluctance Motors Induction Motors (Tesla Motors) Wound Rotor (Continental)
22 Eliminating Rare Earth: Challenges? Lower performance Larger / heavier? Lower efficiency More battery needed? More expensive power electronics? Noise and Vibration?
23 Contents Why are emotors Important? EV emotor Landscape Eliminating Rare Earth Materials Case-Study: Rare Earth Free Motors Conclusions
24 Switched Reluctance Motor: Fundamental Research No magnets? University originated Segmental Rotor Switched Reluctance Motor technology No permanent magnets Larger than rare earth motor though mass similar Application: Electric Vehicle 80kW SR-SRM 80kW Nissan Leaf
25 Switched Reluctance Motor: High Temperature How to match magnet performance? High Temperature operation allows higher power and reduction in system cost and complexity Application: Hybrid Truck
26 Switched Reluctance Motor: New Materials How to beat magnet performance? Materials enabling very high rotational speeds coupled to compact gearbox gives same power output with smaller / lighter motor Application: Electric / Hybrid Vehicles
27 Contents Why are emotors Important? EV emotor Landscape Eliminating Rare Earth Materials Case-Study: Rare Earth Free Motors Conclusions
28 (source: IEA) Conclusions 250M Motors sold in EU each year 12M EV Motors per year by 2030? Elimination and Substitution of NdFeB/Dy can reduce cost and improve environmental footprint Approaches needed to match rare earth performance Rare earth likely still to be the choice for small motors Potential Energy Savings from Electric Motor improvements are enormous: TWh of electricity demand USD 2.8 trillion in electricity costs globally by Gt of CO2 emissions (Equiv. to UK, FR and DE!)
29 James Widmer School of Electrical and Electronic Engineering Merz Court, University of Newcastle Upon Tyne NE1 7RU UK Tel +44 (0) Mob +44 (0) Fax +44 (0)
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