Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM
Alternative magnets for electric drives
The conservation of raw materials is becoming an crucial aspect of the development of electric machines. For instance, rare earth elements are employed the production of magnets for synchronous machines. However, these elements are not only expensive but also in limited supply, which is why they are mostly imported from China. As a result, electric machine manufacturers are actively seeking alternatives. At Fraunhofer IFAM, research is being conducted on materials that are not only more cost-effective but also reduce dependence on rare earth elements. This is of great interest to the industry, given the extreme price fluctuations and China's dominance in rare earth mining.
Resource-efficient production of permanent magnet machines
The rare earth elements neodymium and dysprosium are frequently utilized in electric drives. The utilization of these elements enables the attainment of exceedingly high power and torque densities in permanent magnet electric motors. However, these two elements also represent the primary cost drivers in the production of high-performance permanent magnet electric motors. Consequently, in a project was undertaken in collaboration with other Fraunhofer institutes, with the objective of investigating alternative magnetic materials for a reference motor comprising neodymium-iron-boron (NdFeB) magnets. The objective was to reduce the proportion of rare earth elements while maintaining the performance of the electric machine.
As part of the "Criticality of Rare Earths" project, magnets with a significantly reduced dysprosium content were developed and tested in a 600 W oil pump motor of the VW DSG DQ400 gearbox model, which is used in millions of vehicles. A reduction of up to 43 percent in dysprosium was demonstrated.
Furthermore, the reference motor was enhanced through a series of optimization procedures to achieve an elevated torque density. With a uniform magnet volume, an increase of over 14 percent was attained. Consequently the motor can be manufactured in a more compact and lightweight configuration while maintaining the same torque, thereby reducing material and manufacturing costs.
We are your partner for the development of cost-optimized electric machines
The experts in electric drives at Fraunhofer IFAM are engaged in the development of processes for the cost- and resource-efficient production of electric machines. This encompasses forward-thinking methodologies, such as "Multi-disciplinary Design Optimization" (MDO), which facilitate the expeditious and deliberate development of a motor design across multiple domains. Such electric machines are utilized across a diverse range of industrial sectors, including the automotive and aerospace industries. The applications encompass a diverse range of electric motors, including those utilized in auxiliary units, traction drives, servo systems, and industrial machinery. Should you require any further information or wish to discuss potential solutions in more detail, please do not hesitate to contact us.