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

HeFT认为高能效的稀土同步电机是下一代大功率主桥牵引电动汽车的最佳选择，并提出了一系列基于碳化硅逆变器(转子和定子直接冷却、高压高级绝缘、多屏障转子拓扑结构、波形绕组)和先进材料(先进的GBD磁铁、用于磁铁固定的环氧树脂、电机外壳复合材料、绝缘树脂)的电动同步电机配置的创新挑战。这些创新将产生高效率和低成本的解决方案，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(大众ID.3和菲亚特500)相比，将带来下一步的影响：&gt；800V，减少20%的损耗，&gt；7kW/kg和42kW/L的功率密度，28%的成本更低，50%-66%的材料节约，包括减少60%的稀土含量和&gt；80%的稀土回收利用率。由于这一解决方案仍依赖中国的稀土元素，Heft将与面向稀土永磁体循环经济市场的ERMA行动计划保持一致，并建议：一条替代磁体路线(基于Ce)和两条稀土回收路线，以及旨在为欧洲稀土产业奠定基础的政策促进，到2030年能够提供欧盟20%的需求。HeFT计划8个WPS来实施这些概念，其中5个研究合作伙伴将是围绕设计到x方法开发创新想法的关键，而强大的公司(GKN Automotive、Magneti、VYNCOLIT)将确保HeFT成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，以确保广泛采用Heft解决方案，并与政策制定者一起推动针对欧盟循环市场的监管，这将有助于保持欧盟公司的领导地位，同时提高它们的竞争力和与新的循环商业模式相关的就业机会。

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.