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Objectives
Technical Objectives
Reduction in use of magnets and magnetic components (and REEs) in e-motors, weight reduction in active components up to 50%
Weight reduction of 20% of the actual motor mass at mechanism level
Improve the overall performance of use case e-motors up to 30%
Reduce the lead-time of rotor manufacturing more than 20%
Overall energy efficiency increases by 20%
A recyclability rate >60% of REEs
Specific Objectives
Generate a modelling framework for optimization and designing multi-functional, multi-material magnetic components and structures
Advance the state-of-the-art of magnetic multi-material interfaces and processing parameters of dissimilar materials in additive manufacturing
Advance the state-of-the-art of magnetic multi-material interfaces and processing parameters of dissimilar materials in additive manufacturing
Develop recycling and dismantling of MM-AM components and structures and validate the environmental and economical sustainability of developed solutions
Communicate and disseminate the outcomes, benefits and challenges for the relevant industrial stakeholders
Technology
MultiMag takes the full advantage of multi-material additive manufacturing. Stacked rotor and stator structures, combining dissimilar magnetic and electric insulating materials and built layer upon layer, are developed and demonstrated. Optimized multi-material structures are developed, manufactured and validated to ensure mechanical, thermal, electrical and magnetic performance. Internal structures, enabling e.g. more efficient cooling, are studied and designed. Material savings by topology optimization is demonstrated for weight reduction and economizing the use of REEs in magnets. However, the ambitious objectives of MultiMag cannot be achieved only by implementing MM-AM, but it requires a holistic approach and innovations in all sectors, namely design, materials, manufacturing, use and end-of-life. Each of these vital areas are addressed by MultiMag activities.
Innovations
- View all
- Design
- MM-AM process
- Material
- Circular economy
Design
- Integrated conformal cooling housing
- Multi-optimized component constructions
- Double rotor design
- Segmented magnets to
reduce losses
MM-AM process
- Stacked multi-material AM
rotor structures - Geometrically optimized
MM-AM stator coils for better performance
Material
- Novel light weight structural housing material
- Optimized soft-hard magnetic joints for easy assembly constructions
Circular economy
- Smart, energy efficient products
- Effective extraction, recovery and recycling of rare earth elements
- Easy dismantling due to modular design
Use Cases
In order to have a sharp approach and focus on real industrial issues, MultiMag consortium has defined three real-life use cases in the field of electric machines, representing several different industry domains. With clearly defined development targets and given baseline values and metrics, these use cases guide the consortium’s efforts towards results with high impact.
Use Case 1
General purpose induction motor (SIE)
MM-AM of the low-voltage motor improves its thermal, mechanical and electromagnetic properties. Higher torque performance and weight reduction of multi-material magnetic component enables its use in advanced automation and mobility applications.
Use Case 2
Synchronous permanent magnet brushless motor with axially aligned stator poles (IPCE)
MM-AM of the low-voltage motor improves its thermal, mechanical and electromagnetic properties. Higher torque performance and weight reduction of multi-material magnetic component enables its use in advanced automation and mobility applications.
Use Case 3
Multipurpose Electrical rotary actuator (SEN)
MM-AM allows manufacturing of the hybrid stepper motor technology at a low price with a certain customization between different products for the new space market.