Design, develop and validate an axial flux electrical machine for automotive application
The design optimization of a permanent magnet-less axial flux electrical machine involves multiple physics considerations, including the integration of power electronics (ranging from 400V to 800V) and drive integration. This design also focuses on improving thermal control while meeting automotive standards.
To develop a new framework for the design and analysis of electrical machines, that aims to produce more sustainable products that align with circularity principles, resulting in reduced impact on the environment and mitigating the effects of climate change.
Continuous power densities >23kW/litre and >7 kW/kg or continuous torque densities > 50Nm/litre and >20Nm/kg, for the complete motor including its cooling.
A 20% reduction in losses during typical vehicle operation.
A reduction in the use of rare resources by 60%.
Develop a digital twin of an electrical machine for optimal control
Development of a multiphysics light model to predict the thermal behaviour of the machine based on an accurate evaluation of the losses, especially in the magnetic materials, Electrical Steel and Soft Magnetic Composite.
A digital twin of the electrical machine is constructed using advanced measurements, multiphysics models, and Artificial Intelligence. This digital twin enables real-time monitoring of the machine's detailed thermal behavior. It virtually replicates the various physics aspects of the motor, including electromagnetics, thermofluidics, and mechanics, allowing it to predict electric consumption, electromagnetic status, mechanical output/status, and thermal performance.
Development of an optimal control strategy to maximize the performances based on the digital twin.
A decrease in energy consumption on driving cycles by 2%.
Optimize magnetic materials and the manufacturing process flow of an axial flux electrical machine for mass production and limit the critical raw materials use by recycling the permanent magnet
Evaluating the current manufacturing and recycling processes based on their cost, capability, and environmental impact.
The manufacturing process flow of the axial flux machine can be optimized by exploring novel concepts.
The development and validation of a complete recycling process for permanent magnets involves disassembling the electrical machine, recycling the magnets, and then reusing them in a new electrical machine.
Precise modeling and optimization of magnetic materials are essential for designing an electrical machine and its corresponding digital twin.
The simultaneous optimization of cost efficiency and environmental impact is the goal of co-designing the axial flux machine along with its manufacturing and recycling processes.
A Unit cost for the complete motor at mass production levels (100.000 units/year)
A recyclability rate >60%, of critical raw materials by repurposing permanent magnet without extracting the single rare elements.
Development of an ex-ante and prospective life cycle assessment of an electrical machine
A framework will be created to outline the optimal practices, necessary requirements, and crucial factors for evaluating the environmental impact of an electrical machine with a specific emphasis on its ecodesign.
Developement of prototypes to validate the concept through representative automotive duty cycle
In order to cater to the target market of MAXIMA and the modular nature of the electrical machine, two prototypes with power outputs of 60 kW and 120 kW will be created and produced. These prototypes will then be tested in an industrial setting to evaluate the electrical machine's design, the most efficient control strategy based on the digital twin, and the manufacturing and recycling process flow.