Horizon2020 ReFreeDrive Project: Rare Earth Free e-Drives featuring low cost manufacturing

Peer-reviewed and accepted conference paper for TRA2020 conference (cancelled), published within the TRA Book of Abstracts on 28/05/2020. ABSTRACT: EU-Horizon2020 funded project ReFreeDrive focuses on innovative electric motor designs for automotive industry completely free of rare earth magnets. Compared with the benchmark motors and manufacturers within the electric vehicles industry, ReFreeDrive motors are expected to improve specific torque and specific power by 30%, with a 50% increase in maximum operating speed and power density in power electronics, while halving motor losses. Two technologies, fabricated and die cast induction motor, and synchronous reluctance motor with and without ferrite permanent magnets assistance were analyzed for 200kW and 75kW power levels. Electromagnetic, thermal and mechanical performances of each motor have been optimized for each case, in order to fulfill industry requirements. Low manufacturing cost and reduction of the use of materials have been considered during the design stage, which allowed achieving 15% lower production cost. Prototypes of each kind of motor will be manufactured and tested before the end of the project