Achieving Balance Between Performance, Cost, Efficiency, and Sustainability in E-Motors for OEMs
This report examines the critical challenges that are faced by OEMs in the electric motor industry: finding the optimal balance between performance, cost, efficiency, and sustainability for e-motors. With the growing demand for sustainable transportation, OEMs are under increasing pressure to deliver high-performing, cost-effective, and environmentally conscious electric motors. This report provides a comprehensive analysis of strategies and technologies that OEMs can adopt to address this complex issue.
Table of Contents
- Technological Strategies for Achieving Balance
- Innovative Motor Designs to Improve Efficiency and Cut Costs
- Achieving a Circular Economy: Making Recycling a Priority, Not an Afterthought
- Case Study: Enhancing the Circular Economy through Innovative Redesign of Airbus Components by the University of Strathclyde
- Jill Miscandlon: What Other Projects Has the University of Strathclyde Worked On?
Introduction
As the automotive industry transitions towards electrification, OEMs are tasked with designing and producing electric motors that meet the demanding requirements of consumers, regulators, and the market. Achieving an optimal balance between performance, cost, efficiency, and sustainability is crucial to the success of e-motors in the global automotive landscape. This report will examine ways that this can be achieved and what factors need to be considered.
Overview
Performance: Performance in e-motors encompasses factors such as power output, torque, acceleration, and reliability. OEMs must invest in research and development to improve the power density of motors, enabling higher performance without compromising on size or weight. Additionally, advancements in motor control algorithms and materials are key areas to focus on for enhancing performance.
Cost: Cost considerations are paramount in the competitive automotive industry. OEMs should explore innovative manufacturing processes, economies of scale, and strategic supply chain management to reduce production costs. Furthermore, investment in materials research and development, such as alternative, cost-effective magnet materials, can significantly impact overall motor costs.
Efficiency: Efficiency is a critical factor in determining the range and overall energy consumption of electric vehicles (EVs). OEMs should focus on optimising motor designs to reduce energy losses, minimise friction, and enhance thermal management. Incorporating advanced materials, such as high-performance magnets, and employing advanced simulation tools can lead to substantial gains in motor efficiency.
Sustainability: Sustainability is a rapidly growing concern in the automotive industry, driven by environmental regulations and consumer demand for greener technologies. OEMs must adopt a holistic approach to sustainability, considering the entire lifecycle of e-motors. This includes the responsible sourcing of raw materials, designing for recyclability, and implementing end-of-life disposal strategies that minimise environmental impact.
Technological Strategies for Achieving Balance
Advanced Materials and Manufacturing Techniques
The conversation surrounding the use of rare earth materials and the environmental impact and cost of using them has led to many in the industry actively working to move away from the use of rare earth metals like cobalt and neodymium. The key challenge for the industry is finding alternatives that produce the same or more levels of efficiency as the permanent magnet motor. OEMs need to adapt to new strategies which consider a materials, design, and carbon footprint point of view. Research and development in materials can lead to breakthroughs in magnet technologies, allowing for higher performance and cost-effective solutions. Additive manufacturing techniques can also enhance motor production processes.
The issue of materials in the e-motor industry presents many challenges in various areas including sustainability, sourcing, and cost. To reach the goal of low-cost e-motors, it is important to select the right materials. OEMs are looking at alternative solutions to rare earth materials, but do they solve the problem or just contribute to the environmental impact in another negative way? Organisations within the industry have adopted using more advanced and lightweight materials for electric vehicle production including composite plastics, high-grade steel and aluminium alloys, but this still has a huge environmental footprint, predominantly due to the greenhouse gas emissions of the energy required to process these materials, as well as posing difficulties for dismantling, reusing and recycling the end-of-life vehicles.
Innovative Motor Designs to Improve Efficiency and Cut Costs
Redesigning the architecture of e-motors, including rotor and stator configurations, can lead to efficiency gains without compromising performance. Utilising multi-physics simulation tools can aid in the optimisation of motor designs.
But, what about the constant elephant in the room, cutting costs? As the industry pursues cheaper, high-efficiency e-motors, every area of the production process is being assessed to see where companies can cut costs. With the recent surge of new manufacturing processes and techniques that improve manufacturing efficiency and reduce the cost of manufacturing and the overall cost of the motor, companies need to know which strategies to implement to reach their goal of cheaper e-motors.
Achieving a Circular Economy: Making Recycling a Priority, Not an Afterthought
OEMs are emphasising the significance of sustainability in the automotive industry and actively seeking methods to enhance the sustainability of their motors. This focus has prompted a shift in priorities towards integrating sustainability and environmental consciousness into the design phase without incurring additional costs, a challenge that the industry must address. This balance is easier said than done, challenging the industry to explore cost-effective approaches to successfully integrate sustainability without compromising on other vital attributes of the vehicles.
What is also causing a strain on the industry is evolving government legislations; while sustainability was once considered a "nice-to-have" feature, the UK and EU are now in a circumstance where sustainability measures must be complied with and coupled with a growing environmental consciousness, this has transformed sustainable e-motors from a preference to a necessity. This has left the industry in a state where OEMs and Tier-1 companies are now tasked with finding innovative ways to embed sustainability into the designs of electric motors.
The European Green Deal (EGD)
The EGD is Europe’s growth strategy created to guarantee a climate-neutral, clean circular economy by 2050. The industry is now in a position where they are adapting their methods to comply and meet the objectives of the EGD, with a roadmap to achieve this being laid out by The Circular Economy Action Plan (CEAP) and the New Industrial Strategy for Europe.
‘The CEAP contains a commitment to review the legislation on end-of-life vehicles (ELVs) with the aim to “promote more circular business models by linking design issues to end-of-life treatment, consider rules on mandatory recycled content for certain materials, and improve recycling efficiency”.’
Current E-Motors on the Market
One part of the puzzle is to propose new purposes for the current e-motors at the end of their life, as they were built with sustainability barely being a consideration, let alone a priority, to reduce any negative environmental impact. In a 2023 interview between Automotive IQ and Jill Miscandlon at the National Manufacturing Institute Scotland, University of Strathclyde, Jill gave examples and predictions for the end of the current e-motor vehicle’s life:
“In the short term, we have a lot of e-motors already in the market that were not designed with sustainability in mind, but we still need to process them as efficiently as possible, even if the solution is not optimal.
It will be likely that the current e-motors will either be kept intact and used in a secondary application, if possible, or they will be completely disassembled, with as much of the material recycled as possible.”
New Strategies in Place
Recycling and second-life considerations are integral to achieving sustainability objectives, requiring a fundamental shift in industry perspectives. The automotive sector has progressed to a point where the design of e-motors is well understood, prompting a renewed focus on producing environmentally friendly e-motors from the outset. Recycling and second-life considerations are no longer relegated to the background but are positioned as essential components of the conversation surrounding net-zero goals. In the same interview with Jill, she gave insights into what needs to be done to make positive environmental impacts:
“For future e-motors to provide a truly sustainable future, a full circular economy approach will need to be adopted; this includes the repair of motors and asset life extension, the reuse in secondary applications, and the implementation of remanufacturing activities.
For all these strategies to be implemented, the longer-term goal for e-motors should be to rethink the design and manufacture of components, with an integrated strategy putting an emphasis not only on performance and cost, but also on sustainability issues such as material scrappage rates, disassembly strategies, and full life cycle impact.”
But what’s still on the industry’s mind is knowing whether this can be achieved. How can we ensure that every part of the motor is recyclable after its first life? When we approached Jill with this question, she provided solutions to the redesign phase, to implement secondary life in the production process:
“Recycling should be viewed as one part of the puzzle of e-motor sustainability. If we question more ‘How do we ensure that every part of the motor is optimally processed after its first life?’ This change of emphasis not only alters the basis of the conversation but also opens many more opportunities for us to find real, long-lasting solutions.
For current designs, it will be impossible to fully recycle every part of the motor, with disassembly being a challenge in itself, plus the use of resins and adhesives complicates the removal and recycling of certain components. However, if we open the discussion to include: the reuse of complete motors or individual components, monitoring and repair strategies to extend motor life, as well as remanufacturing options for the reduction of energy use, greenhouse gasses, and air and water emissions, then we have a much larger toolkit to work with, which will ensure that every part of the motor contributes to a sustainable product.”
This transformative approach extends beyond design aesthetics to encompass material selection in the construction of e-motors, emphasising full recyclability. As a result, collaboration between strategists and design teams becomes imperative to achieve the overarching goal of making electric motors not only environmentally friendly in design but also fully recyclable in practice.
Case Study: Enhancing the Circular Economy through Innovative Redesign of Airbus Components by the University of Strathclyde
The University of Strathclyde collaborated with Airbus and the European Space Agency to alter the production of propellant tanks, aiming to address sustainability concerns and contribute positively to the circular economy. The project focused on redefining manufacturing processes, reducing material input, and maximising sustainable opportunities.
Redesigning the Manufacturing Process
The conventional method involved fully machining forged titanium domes, resulting in significant material wastage and high production costs. Through collaboration, metal spinning of aluminum was proposed as an alternative manufacturing route for high-pressure vessels. Metal spinning refined the grain structure, enhancing mechanical and fatigue properties. The outcome was a successful TRL6 design review for a 60-liter aluminum tank, with Airbus anticipating a substantial 30% cost reduction.
The University of Strathclyde's collaboration with Airbus and the European Space Agency resulted in a comprehensive approach to enhance the circular economy. The redesigned manufacturing process, repair strategies, emphasis on reuse, promotion of remanufacture, and efficient recycling practices collectively contribute to sustainability, cost savings, and environmental benefits. This case study serves as a model for future initiatives seeking to integrate circular economy principles into complex manufacturing processes, fostering innovation and responsible resource management. More information can be found on this case study at: NMIS
Jill Miscandlon: What Other Projects Has the University of Strathclyde Worked On?
In addition to the Airbus study, the University of Strathclyde has worked on several other projects that promote circular decision making even further. Learn more on this from Jill, in her own words.
Repair Strategies and Additive Manufacturing
Design for disassembly and repair was identified as critical, integrating targeted repair strategies at the component design stage. The inclusion of embedded sensors allowed for condition monitoring and preventative maintenance. Additive manufacturing was employed to produce full components, presenting opportunities for secondary operations and additional functionality. This approach contributed to efficient repair and remanufacturing operations for various applications.
Reuse with Universal Connectors
Design for second life, either in primary or secondary applications, was emphasised. Consideration was given to the use of individual components or sub-assemblies in downstream markets. The implementation of universal connectors facilitated a plug-and-play approach, enhancing the adaptability and versatility of components for reuse.
Remanufacture for Sustainable Returns
The design for remanufacture was incorporated at the initial design stage, offering benefits in terms of cost, environmental impact, and societal contributions. Findings from nine European automotive remanufacturers indicated significant advantages, including cost reductions of 10-65%, energy reductions of 75-85%, and CO2 emission reductions of 70-90%. A case study on Caterpillar's remanufacturing of cylinder heads showcased impressive reductions in greenhouse gases, water use, energy consumption, waste sent to landfills, and material use.
Recycling for Resource Efficiency
The recycling aspect highlighted substantial benefits, including energy savings of 95% for aluminum, 85% for copper, and 80% reduction in CO2 emissions for steel. Water consumption and pollution were also reduced significantly for steel. Approximately 42% of the copper used in Europe already comes from recycled sources, showcasing the progress in recycling rare earth magnets.
E-Motor Technologies Conference
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