Circular design and manufacturing techniques for next-generation highly-efficient integrated axial flux motor drives for electric vehicles

01 January 2024 → 31 December 2026
European funding: framework programme
Research disciplines
  • Engineering and technology
    • Renewable power and energy systems engineering
electric motor axial flux
Other information
Project description

CliMAFlux will develop novel concepts (e.g., in terms of excitation and cooling) for more performant (e.g., >35% energy loss decrease in driving cycles) axial flux motors, thus reducing the need for rare earth materials by 60%, leveraging high-fidelity multiphysics models (e.g., electromagnetic, thermal, mechanical, and at the system level) and digital twins. Innovative designs and manufacturing processes will be proposed to: (i) increase the power density to >23 kW/l, through novel materials and improved thermal behaviour; (ii) enhance circularity over the lifetime (including >70% recyclability at the end of life); and (iii) ensure cost competitiveness (50% cost reduction) at mass production level (reaching ~€5/kW). The CliMAFlux on-board motors are integrated with the power electronics and mechanical transmission systems. The resulting electric drives will be managed by robust predictive controllers based on the CliMAFlux digital twins, including artificial intelligence (AI) prediction models, which will also facilitate novel functionalities in vehicle (sub)systems, hereby exploiting the full capability of the complete electrified drivetrain. The individual motor (with focus on approx. 90 kW continuous power) and integrated drive system will be benchmarked over a wider range of vehicles, in terms of both performance and environmental impact, on virtual (X-in-the-Loop with digital twin) and hardware test platforms up to TRL 7, i.e., on a research electric vehicle already available at the consortium participants. To achieve these ambitious targets, CliMAFlux brings together the competences of 4 academic partners, 1 industry-oriented RTO, 3 SMEs and 1 LE with dedicated R&D and production facilities in the fields of motor and transmission development, power electronics integration, electrified vehicle systems, automotive design, and life cycle assessment and costing aspects.

Funded by the European Union. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or the European Climate, Infrastructure and Environment Executive Agency (CINEA). Neither the European Union nor the authority can be held responsible for them.