HEFT - Novel Concept of a low cost, high power density and highly efficient recyclable motor for next generation mass produced electric vehicles

HEFT认为，高效节能的稀土同步电机是下一代大功率原轴牵引电动汽车的最佳选择，并提出了基于SiC逆变器（转子和定子的直接冷却，高压高级绝缘，多势极转子拓扑，波浪绕组）和先进材料（先进GBD磁体，磁铁固定环氧树脂，电机外壳复合材料，绝缘树脂）的同步电机配置的一系列创新挑战。这些创新将产生一种高效、低成本的解决方案，将在两种电机拓扑上进行验证，与欧洲两种主要参考汽车IPM商用电机（VW ID.3和FIAT500）相比，将产生下一个影响：bbb800v，减少20%的损耗，> 7kw /kg和42kW/ l的功率密度，便宜28%，节省50-66%的材料，包括60%的稀土含量减少和>80%的稀土可回收率。由于该解决方案仍然依赖于中国的稀土元素，HEFT将与ERMA关于稀土永磁体循环经济市场的行动计划保持一致，并建议：一条替代磁体路线（以Ce为基础）和两条稀土元素回收路线，以及促进欧洲稀土产业基础的政策，到2030年能够满足欧盟20%的需求。HEFT计划8个wp来实施这些概念，其中5个研究合作伙伴将对围绕设计到x方法开发创新想法至关重要，而强大的公司（GKN Automotive， MAGNETI， VYNCOLIT）将确保HEFT的结果具有明确的市场导向并满足行业需求。HEFT计划组织OEM研讨会，以确保HEFT解决方案的广泛采用，同时也与政策制定者一起促进欧盟循环市场的法规，这将有助于保持欧盟公司的领导地位，同时增加与新的循环商业模式相关的竞争力和就业机会。

HEFT considers that an energy efficient rare-earth synchronous motor is the best option for next generation high-power primary axle traction EVs and proposes a set of innovation challenges on electric synchronous motor configuration based on SiC inverters (direct cooling of rotor and stator, advance insulation for high voltage, multibarrier rotor topology, wave windings) and advanced materials (advanced GBD magnets, epoxy for magnet fixation, composite for motor housing, insulation resin). These innovations will result in a high-efficient and low-cost solution that will be validated on 2 motor topologies, which compared to two main reference automotive IPM commercial motors in Europe (VW ID.3 and FIAT500) will lead to next impacts: >800V, 20% reduction losses, >7 KW/kg and 42kW/ l power density, 28% cheaper, 50-66% material savings, including 60% reduction of REE content and >80% REE recyclability rate. As this solution is still dependent on REE from China, HEFT will be aligned with the ERMA action plan towards a circular economy market of rare earth permanent magnets and suggests: one alternative magnet route (Ce based) and two REE recycled routes together with policies promotion towards the foundation of a European rare earths industry, capable of delivering 20% of EU demand by 2030. HEFT plans 8 WPs to implement these concepts, where 5 research partners will be essential for developing innovative ideas around the design-to-x approach, while strong companies (GKN Automotive, MAGNETI, VYNCOLIT) will ensure that HEFT results have a clear market orientation and fulfil the industry needs. HEFT plans to organise OEM workshops to ensure wide adoption of HEFT solutions, but also with policymakers to promote regulations towards the EU circular market that would help maintaining the leadership of EU companies, while increasing their competitiveness and job opportunities linked to the new circular business models.