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Panel Session: Electric Vehicle Boom: A look at the latest trends in manufacturing electric vehicles
Global demand for electric vehicles is booming, with 2023 sales expected to grow 35% after a record-breaking 2022. This explosive growth has led to electric vehicles moving from a 4% share of the overall care market to a 14% share in 2022. Three markets are dominating the EV industry – China, Europe, and the US. China is the frontrunner, manufacturing more than half of all electric vehicles. However, the U.S. is ramping up EV production and by investing more than $90 billion in EV manufacturing. Permanent magnet motors are by far the most commonly used electric motor in the EV market thanks to their high-power density, torque density, and efficiency.
Moderator: Jeff Whalen, Founder & Director, MagCorp
Chris Rainone, Global Supply Chain SME for Critical Materials & Supply Chain, Lockheed Martin
David Miller, President, Magnetic Instrumentation
Developing the North American permanent magnet supply chain for energy technologies:
Industry and government perspectives
This panel discussion will focus on both government and industry efforts to develop a robust North American supply chain of permanent magnets to support the energy sector industrial base (ESIB). Rare earth magnets, such as sintered neodymium-iron-boron (NdFeB) magnets, are especially important to the ESIB as they are critical components of traction motors in electric vehicles and direct drive generators in offshore wind turbines. Yet, nearly all supply chain stages of sintered NeFeB magnets are concentrated in China, posing a potential vulnerability for ESIB supply chains required to meet climate goals.
Moderator: Braeton J. Smith, Argonne National Laboratory
Helena Khazdozian, Advanced Manufacturing & Materials Technology Office, U.S. Department of Energy
Jacob Ward, Office of Manufacturing & Energy Supply Chains, U.S. Department of Energy
Alan Lund, MP Materials
The Department of Energy Critical Material Supply Chain Mission: Accelerate the development of new permanent magnets
Since 2013, the Department of Energy’s Advanced Materials and Manufacturing Technologies Office has supported the Critical Materials Innovation Hub (CMI), which has a primary mission to “accelerate innovative scientific and technological solutions to develop resilient and secure supply chains for rare-earth metals and other materials critical to the success of clean energy technologies”. Among these activities have been the discovery and development of new permanent magnets to substitute for those used in the United States today, especially strong, anisotropic ones such as NdFeB and SmCo.
Panel: Harnessing the Power of Magnet Technology: Advancements, Applications, and Future Trends
Magnet technology has played a pivotal role in revolutionizing design and performance across various industries. This panel will delve into the advancements, applications, and future trends in utilizing magnet technology in motors, consumer, medical and other industries. Experts and industry leaders will explore the latest breakthroughs in magnet materials, magnetization techniques, and designs that enable higher efficiency, power density, and reliability.
The objective of this panel is to provide valuable insights into the transformative potential of magnet technology and inspire discussions on the path forward for its widespread implementation in various industries.
Panel: Magnet Technology in Renewable Energies: Advancing Efficiency, Reliability, and Sustainability
Renewable energy sources, such as wind, solar, and hydro, are becoming increasingly critical in the global transition towards a sustainable future. Magnet technology plays a crucial role in enhancing the performance and efficiency of renewable energy systems. This panel will explore the applications, advancements, and future prospects of magnet technology in renewable energies.
Through insightful discussions and case studies, this panel aims to provide a comprehensive understanding of the transformative potential of magnet technology in advancing the efficiency, reliability, and sustainability of renewable energy systems. Attendees will gain valuable insights into the latest trends, challenges, and opportunities in harnessing magnet technology for a cleaner and more sustainable energy future.
Panel: AI Use Cases in Electric Motors: Enhancing Performance, Efficiency, and Maintenance
Artificial Intelligence (AI) has emerged as a powerful tool in revolutionizing various industries, and its application in electric motors holds immense potential for improving performance, efficiency, and maintenance. This panel will delve into the diverse use cases of AI in electric motors, exploring how it can optimize motor design, enhance control systems, and streamline maintenance processes.
The panelists will explore how AI can optimize motor performance by analyzing real-time operating conditions, adjusting control parameters, and predicting and preventing faults and failures. They will discuss how AI-driven predictive maintenance techniques can reduce downtime, extend motor lifespan, and improve overall operational efficiency.
Panel: Recycling Magnet & Critical Materials: Paving the Way for Sustainable Resource Management
Recycling magnet and critical materials has become a pressing necessity in our quest for sustainable resource management. This panel will bring together experts, researchers, and industry leaders to explore the latest developments, challenges, and opportunities in recycling essential materials, including rare earth elements and other critical resources used in magnets and various high-tech applications.
The panelists will discuss cutting-edge recycling technologies and processes that enable the recovery and reuse of valuable materials from end-of-life products and waste streams. They will highlight successful case studies and initiatives that demonstrate the economic and environmental benefits of recycling these critical materials.
Panel: Electrifying the Roads: Exploring EV Motors & Drives
As the world transitions towards sustainable transportation, electric vehicles (EVs) have emerged as a leading solution to reduce carbon emissions and combat climate change. The heart of any electric vehicle lies in its motor and drive system, which determine its performance, efficiency, and overall driving experience. This panel brings together experts from various fields to delve into the intricacies of EV motors and drives, shedding light on the latest advancements, challenges, and future prospects in this rapidly evolving domain.
Mastering Litz Wire: Winding and Welding Techniques for Enhanced Performance
This presentation commences with an introduction to Litz wire by Mr. Benjamin Braggins. He will explore various types of Litz wire, discuss VDE and UL certifications, cover coating options such as serving and taping, and provide valuable insights into the best design practices for electric motors and magnetic components. Mr. Rajasekhara will continue highlighting the main obstacles in winding and welding processes that involve litz wire and how they can be overcome. From how to control tension to get perfect layering despite the variable morphology of the wire, how to avoid wire untwisting, up to how to get clean and solid wire/terminal welding points with wire with high thermal class and composed of many tiny, twisted wires.
Experimental Comparison Between a MOSFET and GaN FET Inverter for Agricultural Drone UAV’s
Battery-powered UAVs are revolutionizing today’s agriculture where they are used to spray fertilizers and more. These drones use motor drives that need to be lightweight and efficient to maximize working battery life and extend flight time between recharging. Wide-bandgap devices, and specifically Gallium Nitride (GaN) FETs, have demonstrated to improve BLDC motor drives in emobility and robotic applications. This paper will present the characteristics of GaN FETs that reduce weight and improve the motor drive system efficiency.
Inferior performance of electric motors caused by degradation of stator magnetic properties after manufacturing processes
This presentation intends to delve into the subject of post-manufacturing degradation in the magnetic properties of stator cores. The analysis is based on evaluations carried out using Brockhaus measurement systems. Additionally, the presentation will explore the direct correlation between the deterioration in magnetic properties and the inferior performance of various types of electric motor topologies. This discussion can shed light on the importance of maintaining the quality of stator cores to ensure optimal electric motor performance.
Bonded Samarium Iron Nitride – A Case for Automotive Usage
Through the development of improved oxidation-resistant coating technology, Nichia has been able to create a SmFeN PPS resin-bonded magnet with the best long-term durability among rare-earth bonded magnets. Automotive applications, in particular, require PPS resin bonded magnets with superior reliability for long term usage. Nichia’s PPS SmFeN magnetic materials can achieve an irreversible flux loss of ≤3% in air at 150°C and aqueous solution at 120°C, making it suitable for harsh environment applications such as water pumps, oil pumps, and fuel pumps. Elevated conditions of greater than 300°C are required for PPS molding, during which magnetic powder can oxidize and degrade if not protected appropriately. Nichia will discuss the performance against currently used bonded Nd PPS materials through various comparisons.
Iron Nitride – The First New Permanent Magnet in 30 years
ron Nitride permanent magnets have been recognized as a potential breakthrough for the industry. Based on the α”-Fe16N2 compound with high saturation magnetization (exceeding that of NdFeB) and a moderate magnetocrystalline anisotropy, the material pairs technical benefits – attractive magnetic performance and superior temperature stability to NdFeB – with the strategic benefit of being completely rare earth-free, relying instead on abundant commodity raw materials. Iron Nitride will act as an economical substitute for several grades of both sintered and bonded NdFeB magnets. Further, they offer significant advantages in terms of environmental footprint and recyclability.
Niron will address the background of the material, selections of the latest empirical data, implications for device design, and details on the process being taken with industry players to commercialize the first new permanent magnet in over 30 years.
Magnetic Simulations and Measurements for Designing Stray Field Robust Sensors
The presentation will comprise the development of two stray field immune magnet-sensor systems. It will cover the methods in their pre-design process as specific FEM simulations and 3D-Hall sensor measurement before realizing any hardware. Stray field immune sensors are often built by sensor pairs using the gradient principle. So, first stage tests including simulations and Hall measurements on different traces close the magnet and calculating potential sensor pair outputs are very valuable. Both can prove the viability of a devised systems and when successful the practical realization can be initiated. The whole way from pre-design investigations up to the hardware realization of a first sensor will be sketched in the presentation.
System Level Optimization and Validation of High-Fidelity Electric Vehicle Motor Designs
In today’s automotive market, end users expect quality electric vehicles (EV) that meet or exceed the performance metrics of standard petroleum cars. To meet this expectation, EV designs are becoming increasingly complex with many system topology options. This presents both a challenge and a significant opportunity for EV designers. To gain a competitive edge in the market, innovative EV system designs require rapid validation and optimization with realistic component-level simulations. In this presentation, we focus on integrating fast and accurate motor simulations with system level EV designs. This methodology provides EV designers with solutions for rapid validation and optimization of motor designs that satisfy cutting-edge EV system specifications and corresponding design topologies. Furthermore, integrating system and component-level simulations is essential to enable a digital twin of a physical EV that can provide valuable information on motor performance within the EV operating environment. We expect that this integrated simulation approach will empower EV designers to rapidly deliver innovative and impactful EV system designs.
Discovery of rare-earth lean high-performance hexaferrites to neo-magnets
We present here our newly discovered crystallographic site substituted high-performance hexaferrites to rare-earth cobalt to neo magnets applicable in vehicle, wind turbine, magnetic cooling, and other household technologies.
The research is supported by the Critical Materials Institute, an Energy Innovation Hub funded by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Materials and Manufacturing Technologies Office.
Panel Session: Empowering Tomorrow: Trends in Electric Motor Control
Electric motor control is at the heart of various industries, from automotive and manufacturing to energy efficiency and home automation. This panel session will bring together key stakeholders from the electric motor industry – motor manufacturers, chip makers, and analysts – to discuss the latest trends, innovations, and market dynamics that are shaping the future of electric motor control.
Permanent Magnets for the 21st Century: Where are we and where do
we go from here
This presentation will cover the permanent magnets developed . .Application space for the various magnets and limitations of the magnets will be discussed. Domestic production of rare-earth metals hampered by environmental issues and possibility of production of metal alloy directly from the oxides will be presented.
The Future of Electric Motors: Demand in The Billions, Regulatory Mandates, and Design Optimization
This session offers a deep dive into the future of electric motor markets, technology, and design innovation. There are a number of exciting, yet complex, movements shaping up around this space. To start, the world will require an abundance of electric motors in just about every sector imaginable of a very different variety than conventional offerings.
Macro trends—such as mass electrification and automation—are pushing global demand for specialized electric motors to over a billion units annually in a sector valued at over $200 billion.
Analysts project this booming electric motor need will occur in a long list of verticals: HVAC equipment, e-mobility, consumer electronics, household appliances, robotics, medical devices, aerospace, defense, and unmanned vehicles.
A Technology Roadmap to Reduce Cost in Performance Materials: reduction, refinement and substitution
Barely a decade after the 2011 Rare Earth crisis, the world entered a second black swan event in the form of the Covid-19 pandemic. It fueled supply chain disruptions and threats of regional strangulation of critical materials o Europe and the Americas. Yet, the demand for NdFeB materials continues to surge with the growth of: high-efficiency motors, mobile consumer electronics, Electric Vehicles and clean energy solutions. Solutions to curb the dependence on both Light Rare Earths and Heavy Rare Earths, has primarily driven the advancement of NdFeB materials and their performance.
We review a variety of parallel technological strides in material advancements by Yunsheng to optimize performance, reduce dependence on LRE and HRE, and enable costdown in magnet cost. We will investigate the latest production-ready technologies being used. These technology solutions include: grain refinement, ternary Rare Earth material substitution, HRE-free and low-HRE materials, and Grain Boundary Diffusion (GBD) technologies.
Case studies: Optimizing the magnetic quality of the Formula Electric Belgium and the Innoptus Solar Team electric race cars
As a proud sponsor of both the Belgian Formula Student and the Belgian Innoptus Solar electric race teams, Magcam has effectively employed its magnetic field camera technology and application expertise to enhance the performance of the permanent magnet rotors used in the electric motors in their respective electric race cars.
The Formula Electric car is powered by four radial-flux motors, whereas the Innoptus Solar car operates with an axial-flux motor. In both scenarios, we started the optimization process by measuring a large quantity of individual magnets using our magnetic field camera scanner. From the resulting magnetic field maps, detailed quality parameters were extracted, including overall magnet strength, magnetization angle error and localized magnetic homogeneity. By ranking these magnets based on the derived quality parameters, we were able to select the highest quality magnets for rotor assembly. This first crucial step assures that only qualified magnets are used. The assembled rotors were subsequently measured by Magcam's advanced radial/axial-flux rotor scanner.
How high-temperature superconducting magnets could unlock the energy source of the future
Since the fusion ignition breakthrough at the Lawrence Livermore Laboratory in late 2022,
billions of dollars have been funneled into achieving commercial fusion energy at scale and international
sprint has ensued to be the first company to achieve it. As a clean, limitless energy source, fusion could
solve the world’s energy problems and make today's climate change debate moot. Yet, to achieve
commercial fusion energy at scale, the world needs more of a critical component that is in short supply -
high temperature superconducting (HTS) magnetic wire. HTS magnetic tape is the only material that can
generate a strong enough magnetic field to achieve fusion energy in a device that is substantially smaller
than alternative technologies. This keynote talk will cover how the latest advancements in HTS magnets
are impacting the race for fusion energy and how one community aims to create an ecosystem to
support technological advancements in HTS magnets.