EV emotors without Rare Earth Materials

(1)

EV eMotors

without Rare

Earth

Materials

(2)

Centre for Advanced

Electrical Drives

Part of the Power Electronics, Drives and Machines Group

Centre for

Advanced Electrical Drives

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:

–

(4)

Centre for Advanced

Electrical Drives

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

(5)

Contents

• Why are eMotors Important?

• EV eMotor Landscape

• Eliminating Rare Earth Materials

• Case-Study: Rare Earth Free Motors

• Conclusions

(6)

Centre for Advanced

Electrical Drives

Contents

•

Why are eMotors Important?

• Conclusions

Centre for Advanced

Electrical Drives

(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)

Centre for Advanced

Electrical Drives

“Large

generators”

RARE EARTH MAGNET MOTORS

“The

class

leader”

INDUCTION MOTORS

“The

traditional

choice”

(10)

Centre for Advanced

Electrical Drives

So how are rare earth

(11)

Neodymium Magnets

3 mm NdFeB magnet

≈

13 Amps through 200

turns of copper

+

(12)

Centre for Advanced

Electrical Drives

Dysprosium Doping

(13)

EV eMotor Landscape

RELUCTANCE MOTORS

“Difficult and

noisy?”

WOUND ROTOR MOTORS

“Large

generators”

RARE EARTH MAGNET MOTORS

“The

class

leader”

INDUCTION MOTORS

“The

traditional

choice”

(14)

Centre for Advanced

Electrical Drives

Rare Earth Magnet Problems

(Brown et al, JoP, 2014)

31,03

25,05

23,41

39,53

49,1

120,38

171,6

0

50

100

150

200

250

300

Interior Permanent

Magnet Motor

Switched

Reluctance Motor

Induction

Motor

USD

(

$

)

NdFeB

Copper

Steel

(Dorrell et al, IEEE, 2010)

71%

Materials Cost

30kW Traction Motors

(15)

Rare Earth Magnet Problems

0 0,5 1

(16)

Centre for Advanced

Electrical Drives

EV eMotor Landscape

RELUCTANCE MOTORS

“Difficult and

noisy?”

WOUND ROTOR MOTORS

“Large

generators”

RARE EARTH MAGNET MOTORS

“The

class

leader”

INDUCTION MOTORS

“The

traditional

choice”

(17)

Rare Earths & Motor Size

6MW ~2T ~3kW/kg

80kW ~2kg ~40kW/kg

200W ~2g ~100kW/kg

(18)

Centre for Advanced

Electrical Drives

cooling

– Reduce dependence

on Dy

• Reduced Dysprosium

content

– E.g. Hitachi metals

(BM

W

(20)

Centre for Advanced

Electrical Drives

Substitute NdFeB and Dy

• SmCo

– Excellent at high

temperatures

– Same issues as NdFeB

• Ferrite magnets

– Low cost

– Low performance

– Demagnetisation risk

(Kim et al, IEE IA, 2013) (M otorBrain F P7 Pro ject )

(21)

Rare Earth Free

• Reluctance motors:

– Synchronous

Reluctance Motors

– Switched

Reluctance Motors

• Induction Motors

• Wound Rotor

(T es la M ot ors ) (C ontinen

(22)

Centre for Advanced

Electrical Drives

• Lower performance

– Larger / heavier?

• Lower efficiency

– More battery needed?

• More expensive power

electronics?

• Noise and Vibration?

Eliminating Rare Earth:

Challenges?

(23)

Contents

•

Case-Study: Rare Earth Free Motors

(24)

Centre for Advanced

Electrical Drives

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

(25)

Switched Reluctance Motor:

High Temperature

• How to match magnet

performance?

– High Temperature

operation allows…

– higher power and…

– reduction in system cost

and complexity

(26)

Centre for Advanced

Electrical Drives

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:

(27)

Contents

(28)

Centre for Advanced

Electrical Drives

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:

– 42 000 TWh of electricity demand

– USD 2.8 trillion in electricity costs globally by 2030

– 29 Gt of CO2

emissions (Equiv. to UK, FR and DE!)

(29)

James Widmer

Centre for Advanced Electrical Drives

School of Electrical and Electronic Engineering

Merz Court, University of Newcastle Upon Tyne

NE1 7RU UK

Tel +44 (0)191 208 3016

Mob +44 (0)7896 514 320

Fax +44 (0)191 208 8180

EV emotors without Rare Earth Materials

EV eMotors

New and Renewable

thermal platforms (JMAG, Infolytica, Ansys)

Prodrive, Protean, Avid, Sevcon, Zytek

• Conclusions

Motor Facts

Contents

“Large

3 mm NdFeB magnet

RARE EARTH MAGNET MOTORS

0

Induction

noisy?”

Contents

cooling

– Low cost

• Lower performance

Switched Reluctance Motor:

performance?

performance?

Conclusions

• Potential Energy Savings from Electric Motor

[email protected]