CAREER: Magnetically Integrated Electric Drive with Rare-Earth-Free Motors

电动机和发电机在各种工业中发挥着至关重要的作用，促进了电动汽车的广泛采用，提高了工业生产率，并利用了可再生能源。尽管如此，现有的技术严重依赖于昂贵的稀土永磁体，这对实现可持续发展目标和促进电气化工作构成了重大障碍。到2050年，为实现可持续能源和交通目标，对稀土永磁体（如钕铁硼）的需求预计将激增20倍以上。预计海上风力涡轮机和电动汽车应用对稀土磁铁的需求将分别达到36.3% （273.7 kt）和35.3% (266 kt)，占总需求的70%以上。因此，确定不含稀土元素但保持高性能和效率的电机驱动器是一个重要的研究领域。该CAREER项目旨在开发一种磁集成电驱动系统，该系统具有拓扑优化的无磁无刷绕组场磁开关（WFFS）电机，从而消除了对昂贵的稀土永磁体的需求。该研究包括优化电机设计以消除低效磁通路径，共同设计电机和逆变器以获得高转矩密度和热性能，以及精确量化电机和驱动器的损耗以开发先进的控制技术。这项研究的结果对各个领域有更广泛的影响，包括电动汽车、可再生能源系统、更多的电动飞机和工业过程，其中电力驱动是至关重要的组成部分。通过提供稀土磁铁驱动的替代方案，该项目旨在彻底改变工业，并为可持续和高功率密度的电力驱动的发展做出贡献。该研究还解决了与稀土材料相关的环境问题和供应链挑战，促进了运输和可再生能源领域的可持续性。研究成果将有助于该领域的知识体系，并对向清洁能源和可持续运输系统的过渡产生持久影响。该奖项反映了美国国家科学基金会的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

Electric motors and generators play a crucial role in diverse industries, facilitating the widespread adoption of electric vehicles, enhancing industrial productivity, and harnessing renewable energy sources. Nonetheless, existing technologies heavily depend on costly rare-earth permanent magnets, which present significant obstacles to achieving sustainability objectives and promoting electrification efforts. The demand for rare-earth permanent magnets, such as neodymium iron boron (NdFeB), is expected to surge more than 20 times to fulfill sustainable energy and transportation goals by 2050. The projected demand for rare-earth magnets in offshore wind turbine and electric vehicle applications will reach 36.3% (273.7 kt) and 35.3% (266 kt), respectively, which is more than 70% of the total demand. Therefore, identifying motor drives that are free from rare-earth elements yet maintain high-performance and efficiency is a significant area of research. This CAREER project aims to develop a magnetically integrated electric drive system with a topologically optimized magnet-free and brushless wound-field flux-switching (WFFS) motor, eliminating the need for expensive rare-earth permanent magnets. The research involves optimizing the motor design to eliminate inefficient magnetic flux paths, co-designing the motor and the inverter for high torque density and thermal performance, and accurately quantifying motor and drive losses for advanced control technique development. The outcomes of this research have broader implications for various sectors, including electric vehicles, renewable energy systems, more electric aircraft, and industrial processes, where electric drives are vital components. By providing an alternative to rare-earth magnet-based drives, the project seeks to revolutionize industry and contribute to the development of sustainable and high-power density electric drives. The research also addresses environmental concerns and supply chain challenges associated with rare-earth materials, promoting sustainability in the transportation and renewable energy sectors. The research outcomes will contribute to the body of knowledge in the field and have a lasting impact on the transition to cleaner energy sources and sustainable transportation systems.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.