James Widmer – EV eMotors without Rare Earth Materials

EV eMotors
without Rare
Earth
Materials
James Widmer
[email protected]
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)
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
New and Renewable
Energy (Small / Large)
High Volume Products
(Low Cost, Efficiency)
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
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
Partnerships
 Aerospace: Airbus, BAE Systems,
Goodrich, United Technologies, QinetiQ
 Automotive: Renault, Daimler, JaguarLandrover, 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
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
Contents
•
•
•
•
•
Why are eMotors Important?
EV eMotor Landscape
Eliminating Rare Earth Materials
Case-Study: Rare Earth Free Motors
Conclusions
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
Contents
•
•
•
•
•
Why are eMotors Important?
EV eMotor Landscape
Eliminating Rare Earth Materials
Case-Study: Rare Earth Free Motors
Conclusions
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
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)
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
Contents
•
•
•
•
•
Why are eMotors Important?
EV eMotor Landscape
Eliminating Rare Earth Materials
Case-Study: Rare Earth Free Motors
Conclusions
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
EV eMotor Landscape
INDUCTION MOTORS
“The
traditional
choice”
WOUND ROTOR MOTORS
“Large
generators”
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
RARE EARTH MAGNET MOTORS
“The
class
leader”
RELUCTANCE MOTORS
“Difficult and
noisy?”
So how are rare earth
materials used in eMotors?
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
Neodymium Magnets
3 mm NdFeB magnet
≈
13 Amps through 200
turns of copper
+
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
Dysprosium Doping
(Brown et al, JoP, 2014)
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
EV eMotor Landscape
INDUCTION MOTORS
“The
traditional
choice”
WOUND ROTOR MOTORS
“Large
generators”
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
RARE EARTH MAGNET MOTORS
“The
class
leader”
RELUCTANCE MOTORS
“Difficult and
noisy?”
Rare Earth Magnet Problems
300
Materials Cost
30kW Traction Motors
250
(NdFeB - $132/kg)
USD ($)
200
150
171,6
71%
NdFeB
Copper
Steel
100
120,38
50
0
39,53
49,1
31,03
25,05
Interior Permanent
Switched
Magnet Motor
Reluctance Motor
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
23,41
Induction
Motor
(Brownetetal,al,IEEE,
JoP,2010)
2014)
(Dorrell
Rare Earth Magnet Problems
‘Normalised’ GHG Emissions from Life Cycle Assessment (LCA)
1
0,5
0
NdFeB Magnet
Copper
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
Aluminium
Steel
Polypropylene
(Unattributed…)
EV eMotor Landscape
INDUCTION MOTORS
“The
traditional
choice”
WOUND ROTOR MOTORS
“Large
generators”
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
RARE EARTH MAGNET MOTORS
“The
class
leader”
RELUCTANCE MOTORS
“Difficult and
noisy?”
Rare Earths & Motor Size
Application
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
Power
Magnet Mass
Metric
6MW
~2T
~3kW/kg
80kW
~2kg
~40kW/kg
200W
~2g
~100kW/kg
Contents
•
•
•
•
•
Why are eMotors Important?
EV eMotor Landscape
Eliminating Rare Earth Materials
Case-Study: Rare Earth Free Motors
Conclusions
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
Reduced NdFeB and Dy
• Hybrid Magnet /
Reluctance Motors
• Improved motor
cooling
– Reduce dependence
on Dy
– E.g. Hitachi metals
diffusion process
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
(BMW i3)
• Reduced Dysprosium
content
Substitute NdFeB and Dy
• SmCo
– Low cost
– Low performance
– Demagnetisation risk
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
(MotorBrain FP7 Project)
• Ferrite magnets
(Kim et al, IEE IA, 2013)
– Excellent at high
temperatures
– Same issues as NdFeB
Rare Earth Free
• Reluctance motors:
• Induction Motors
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
(Continental)
• Wound Rotor
(Tesla Motors)
– Synchronous
Reluctance Motors
– Switched
Reluctance Motors
Eliminating Rare Earth:
Challenges?
• Lower performance
– Larger / heavier?
• Lower efficiency
– More battery needed?
• More expensive power
electronics?
• Noise and Vibration?
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
Contents
•
•
•
•
•
Why are eMotors Important?
EV eMotor Landscape
Eliminating Rare Earth Materials
Case-Study: Rare Earth Free Motors
Conclusions
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
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
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
80kW
Nissan Leaf
80kW SR-SRM
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
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
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
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
Contents
•
•
•
•
•
Why are eMotors Important?
EV eMotor Landscape
Eliminating Rare Earth Materials
Case-Study: Rare Earth Free Motors
Conclusions
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group
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!)
Centre
for Advanced
Electrical Drives
(source: IEA)
Part of the Power Electronics, Drives and Machines Group
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
[email protected]
Centre for Advanced
Electrical Drives
Part of the Power Electronics, Drives and Machines Group