In preparation for the Advanced E-Motor Technologies 2025 conference, Automotive IQ interviews Torsten Knorr, Senior Manger Electromagnetic and Thermal Layout and NVH of E-Machines at SEG Automotive, to discuss strategies to reduce rare earth material use in e-motor designs while preserving performance and efficiency.

Torsten shares how SEG Automotive is balancing cost-efficiency, performance, and efficiency through the use of innovative cooling systems, optimisation techniques, and cutting-edge simulations. Torsten addresses the challenges of minimising rare earth elements while maintaining motor performance and emphasises the significance of new technologies in achieving these goals, offering valuable insights for the future of sustainable e-motor development.

Interview highlights include:

• Effective methods for reducing rare earth materials while maintaining performance and efficiency 
• Key technologies enabling the shift away from rare earth materials in e-motor design 
• Challenges and solutions to reduce rare earth materials 

Get your copy of Dr.-Ing. Alexander Rosen's presentation from the 10th Advanced E-Motor Technology 2023 conference.

Presentation highlights: 

• In-wheel motors with a new type of motor topology and innovative inverter may increase EV ranges by >20%
• Minimised usage of magnets and iron material and cost-effective manufacturing concept make in-wheel motors competitive to central drive units
• A reduction of purchase and operating costs of electric vehicles by >€4,000 is possible. 

We're continuing the topic of efficient in-wheel motors at the 2024 E-Motor Technology conference, with some exciting updates since February 2023. 

The industry has moved from designing the e-motor as an individual component in the system, to adopting a system’s approach and designing the e-motor to fit into the wider system. Though beneficial in many ways, system integration can present some challenges to the motor producer, so it’s important for companies to know the most effective ways to design the e-motor in relation to the entire system.

Ahead of the E-Motor Technologies 2024 conference, Automotive IQ interviewed Dr. Fabio Dohr, Head of Platform Portfolio Electric Vehicle Drives at ZF Group to understand how the complete powertrain system can be optimised from a system-level approach.

“There are several e-motor technologies available at the moment. The question is, will there be a consolidation and if so, in favour of which technologies? Furthermore, there is not much standardisation yet. As a result of that, there is still a broad variety of requirements, like when it comes to packaging. This can be challenging, especially for a Tier-1, as reuse across customers is crucial to be successful, but on the other hand, this is a great chance to create scale effects. Typically, something an OEM has much more limit in. We at ZF tackle this challenge with a modular kit approach which is the basis for all our customer projects.” - Dr. Fabio Dohr

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.

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?