Author: telliott

COP 26: creating a sustainable passenger car solution

Posted on by telliott

Before joining AEM as Chairman in March 2021, Peter Fleet had already enjoyed a highly successful 30-year career at Ford Motor Company. Having most recently held the role of Group Vice President and President of Asia Pacific, Peter has an encyclopaedic knowledge and understanding of the global automotive sector.

That’s why on 10 November, Peter will talk at our COP26 event, Novel Electrification through Advanced Sustainable Technologies (N.EAST), about the changing passenger car market, and what the industry needs to do to make the sector truly sustainable.

By 2030, Deloitte estimates that more than 90% of global passenger car and light commercial vehicle production will consist of electric vehicles (EVs). While this is clearly a step in the right direction when it comes to decarbonising road transport, it does not solve the sustainability issues around passenger cars in its entirety.

Much has been said about sustainability concerns around EV batteries, but similar issues must also be raised about EV motors as well.

Ever since the first hybrid cars came to market, electrified vehicles have traditionally been driven by permanent magnet (PM) motors. As the EV market gathered pace, PM motors became the de facto solution, and the supply chain built itself around this technology.

But PM motors have a number of characteristics that threaten to undo much of the good work that the automotive sector is doing around decarbonisation.

Firstly, the rare earth materials used in the magnets of PM motors are highly damaging when mined and processes. Every tonne of rare earth material taken from the ground produces up to 1.4 tonnes of radioactive waste, 200m3 of acid-containing sewage water, 60,000m3 waste gas containing hydrochloric acid and 27.6 tonnes of CO2.

The pricing of these materials is also highly volatile, making it difficult for manufacturers to accurately predict the cost of scaling PM motor technology to the many millions needed by 2030.

Meanwhile, PM motors are costly and inefficient to recycle owing to the use of magnets and copper.

So, the question remains, how do we make EVs truly sustainable, in time for mass global adoption in the passenger car market?

For ideas from some of the automotive and engineering sectors’ brightest minds, be sure to join us for N.EAST at 15:00 on 10 November at COP26 in Glasgow or virtually via COP26’s YouTube live channel.

AEM to show EV motors need not cost the earth at COP26

Posted on by telliott
  • AEM’s event at COP26 on 10 November will explore how EV motors can be produced and recycled sustainably
  • Most EV motors currently use rare earth metals, obtained through a mining process that is harmful to the environment
  • ‘Novel Electrification through Advanced Sustainable Technologies’ event to include speakers from AEM, the University of Nottingham, Hypromag and Tevva.

1 October 2021 Press Release

Sustainable EV motor manufacturer, Advanced Electric Machines (AEM), will set out why the production of electric vehicles (EV) motors doesn’t need to be harmful to the environment, as it takes to the stage at COP26. At 15:00 on 10 November in the Green Zone, AEM’s event, titled ‘Novel Electrification through Advanced Sustainable Technologies’ will look at why today’s EV motors are so problematic, and what can be done to ensure that the next generation of components allow EVs to be genuinely sustainable.

AEM’s CEO, Professor James Widmer, and Chairman, Peter Fleet, will be joined at COP26 by an impressive panel of speakers, who will each give their own perspective on how EV motors can be made more sustainable. These include Professor Mark Johnson, Director of the EPSRC Centre for Power Electronics at the University of Nottingham, Professor Allan Walton, Founding Director of Hypromag, and David Thackray, Sales and Marketing Director at Tevva.

Currently, the vast majority of EVs in production are driven by a permanent magnet motor (PMM), which contains rare earth metals. The mining of these materials is highly damaging, with the extraction of one tonne of rare earth metal creating 1.4 tonnes of radioactive waste and 27.6 tonnes of CO2.

The speakers at AEM’s COP26 event have all developed ways to reduce or eliminate rare earth mining from the EV motor supply chain, either by developing pioneering motor technology or incorporating it into their products.

AEM’s patented motor technology achieves higher levels of performance and efficiency than equivalent permanent magnet motors, without using rare earth metals. It has also eliminated the need to use copper in its motors, making them easier to recycle than conventional motors.

Further information about the ‘Novel Electrification through Advanced Sustainable Technologies’ event will be announced via AEM’s website and social media channels in the coming weeks.

For any media enquiries please contact:

Alex Michaelides, Torque Agency Group

amichaelides@torqueagencygroup.com | +44 (0) 7802 865 732

Alex Juggins, Torque Agency Group

ajuggins@torqueagencygroup.com | +44 (0) 7470 498 175

Making rare earth materials as sustainable as possible

Posted on by telliott

Rare earth magnets are increasing in demand as we shift to a zero-carbon economy, and electric vehicles especially use a lot of magnets. Currently, less than 1% of these magnets are actually recycled, so as the demand for them increases, as does the scale of extraction and processing of the rare earth materials, which is creating huge environmental issues.

RaRE is a project underway at Advanced Electric Machines that has set out to answer: how do we extract rare earth materials from waste electronics and recycle them back into magnets to be used in motors, and do we do this in a sustainable way? 

Why?

There are a considerable number of individual magnets in the non-drive mechanisms in a car. Many of these magnets are tiny, so they cannot easily be replaced with magnet-free technology. The question then becomes, how do we make these irreplaceable magnets as sustainable as possible?

For all the time and effort invested, recycling rare earth materials has been broadly unsuccessful. The current process is to either melt magnets back to a master alloy or use solvent extraction to extract rare earth materials. Not only are these processes energy-intensive, but they also require magnets to be separate from other components in the motor housing, which often isn’t the case. With a limited supply available, manufacturers are looking for a more practical and cost-effective way of operating systems using magnet-based technology.

Working with the leader in magnet recycling and manufacturing, HyProMag, and the University of Birmingham, our goal is to broaden the range of scrap for the extraction of magnets and scale-up the extraction and recycling processes to make as many motor technologies as sustainable as possible.

The recycled magnets will be used in the bespoke ancillary motors designed and manufactured by AEM, and applied by Bentley Motors. Unipart will then develop a scalable manufacturing route for the volume production of this design. 

The Opportunities

There are currently no motor designs on the market using recycled rare earth materials. Aside from making this an industry first, there are broader opportunities from the outcome of the RaRE project.

For instance, the scrap separation process that will be developed has applications within both global waste handling and waste handling facility designs. There are also benefits for recycled rare earth production facilities from the models of scrap processing and magnet manufacturing that will be developed, and all these processes and materials will be applicable across several sectors, creating a huge number of opportunities in different applications.

These outcomes from RaRE will present an opportunity to create a competitive advantage for UK motor manufacturing by developing a differentiated supply chain for motors and power electronics, which is expected to grow to £5 billion by 2025. The cost-effective production of magnetic materials could turn the UK into an exporter of magnets for tractions motors and inherently protect the UK from future supply issues. 

Our Solution

The University of Birmingham developed its patented Hydrogen Processing of Magnet Scrap method for use with neodymium iron boron (NdFeB) magnets. This process reduces these types of magnets to a de-magnetised powder that can be mechanically removed from a component. The powder is then purified and remanufactured by resintering, where it is compacted into a solid form using heat or pressure.

This solution allows the extraction of magnets from a wide variety of sources, from automotive products to loudspeakers and hard disk drives, creating immense scale-up opportunities for the project.

AEM are also developing prototype motor designs that have been optimised to use these recycled rare earths whilst meeting the high performance and reliability criteria required by vehicle manufacturers.

Read the RaRE press release: https://advancedelectricmachines.com/new-bentley-motors-project-announcement/

Delivering a compact, integrated, and cost-effective E-Axle with Bentley

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AEM’s OCTOPUS project will deliver an E-Axle, free of rare earth materials, that uses next-generation integrated power electronics to create marketing-leading power density and packaging characteristics in line with Bentley’s needs.

We’ve previously worked with Bentley on the APEX motor technology project, and the OCTOPUS project builds on this work by applying leading-edge materials and manufacturing processes to push performance characteristics beyond APEX.


Why?

Delivering the ultimate passenger car E-Axle solution is a challenge that touches many issues: sustainability, rare earth material supply issues, CO2 emissions in production, CO2 emissions in use and recyclability at the end of life.

The key issues to address are four-fold:

  • How do we extract rare earth materials sustainably?
  • How do we put together the materials?
  • How efficiently can we put together these materials?
  • When we’re finished with those materials, how do we make sure we dispose of them in the most sustainable way?


The OCTOPUS Project

The OCTOPUS project sees us apply a cutting-edge approach to an iconic UK brand — and no manufacturer is more demanding than Bentley. But our goal is not simply to narrow its application to best-in-class performance vehicles. This is a technology that can be applied to all vehicles — not just the 0.1%.

The simulation toolkit, test programmes and test rigs can be applied to the automotive and broader transport markets. These can be developed to become vital assets to other automotive organisations leading the development of electrification technologies. The wire production methodology and additive manufacturing process routes developed through the OCTOPUS project will also be suitable for use in the wider component manufacturing market.

Partners on the project include AEM, TTPi, Hieta, Talga, Hartree, Diamond Light Source, University of Bath and Bentley Motors.


The Solution

AEM aims to use everything available in the market in the best way to deliver a world-changing technology solution and push performance characteristics beyond those of the APEX project. The result is an E-Axle solution that is more power-dense, more manufacturable and has stronger performance characteristics.

To achieve this, we used Europe’s largest supercomputer network, one of the world’s largest microscopes and world-leading test and validation. We also brought together the latest carbon-based super materials — graphene and carbon monotube — with traditional materials thinking. The solution has reduced costs and footprint by applying leading-edge materials and manufacturing processes to remove rare earth materials and copper from the process.

From this, we developed a cutting-edge manufacturing process working alongside traditional manufacturing to deliver an integrated solution that reduces the system’s overall manufacturing and assembly costs. The new manufacturing processes can be energy-intensive, and so we only use the technology when necessary. 

By using the installed asset base of the UK’s advanced manufacturing capability, manufacturers don’t have to spend millions on new tech and redesign processes and systems that already deliver low-cost economies. This also helps secure manufacturing jobs in the UK and encourages retraining of employees.

There are also wider opportunities for partners to become involved in developing an end-to-end supply chain, providing an opening for using the technology in sectors beyond automotive. AEM has developed a truly sustainable solution to future transports that is world-leading in its performance, cost and recyclability. 


Keen to learn more? Stay tuned in to find out how it’s going.

More about AEM’s passenger car applications: https://advancedelectricmachines.com/applications/passenger-car/

Read the OCTOPUS press release: https://www.bentleymedia.com/en/newsitem/1128-bentley-motors-looks-to-the-future-of-electric-drive

OCTOPUSDownload

Delivering sustainable and reliable electrification of agricultural vehicles

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AEM’s ElecTra project will make the UK a leader in the electrification of agriculture by delivering an integrated, cost-effective hybrid powertrain optimised for the agricultural sector’s needs.

We’ve partnered with CNH Industrial, home to some of the world’s most innovative agricultural machinery brands and the leader in the Dow Jones Sustainability Indices, World and Europe for machinery and electrical equipment for the last decade.

Why?

ElecTra is one of the most challenging projects in terms of electrification. 

Globally, governments and industry are looking to find ways for more sustainable food production and agriculture while dealing with the threats of market instability and climate change. Addressing this challenge goes to the heart of the issue of sustainability in food production.

There is also the issue of use cycles in the agricultural industry.

While a consumer vehicle sits idle for most of the day after being used for only an hour or so, heavy-duty agricultural vehicles need to be in service for up to 16 hours every day during sowing and harvesting periods. The lack of reliability of current technology has a significant and immediate cost impact on the income and security of our food sources. That’s why the solution has to be practical and credible and demand reliability for the industry.

In many ways, the electrification of agriculture is the ultimate test for the electrification industry. Agriculture is one of the largest industrial producers of greenhouse gases. Therefore, the journey to net zero in farming and agriculture will not be a single step but a series of steps that edge the industry closer to zero-carbon emissions. 

The ElecTra Project and our Partners

Project partners on the ElecTra project include AEM, CNH Industrial, SR Technologies, Semikron and Bath University.

Working with CNH Industrial, our remit looks at all aspects of the journey to zero-carbon food production, from the movement of hay bales to the delivery of food to retailers and distributors. We’re extending the envelope of how much electrification can be used on a farm through our innovation.

The company’s agricultural brands include Case IH, New Holland Agriculture and Steyr for tractors and farming machinery. Its leading-edge technology helps increase the economic viability of farming, maximise density and ensure crops are harvested in optimal commercial conditions. Their AI-powered, self-driving tractors can be programmed to pick crops in ideal conditions, whether to avoid or take advantage of weather or optimal commercial conditions.

CNH Industrial is also home to commercial vehicles brands, such as Iveco trucks and buses, so there is scope for application across these areas as well. The electric motor, transmission, power electronics, VCU hardware/software designs and simulations will all be applicable beyond agriculture, with uses in the off-highway, low-volume commercial vehicle and passenger car markets.

There is also a critical opportunity to de-risk the existing mechanical process and secure crop density and food supply. Currently, the systems used represent a risk, with hydraulic transmission reliant upon oil. The implication of an oil leak during harvesting or sowing can be the removal of entire fields from crop usage for up to two years. Shifting away from these systems and towards electrification helps secure the livelihoods of farmers and the availability of crops.

Addressing the unique challenges of electrifying agricultural vehicles, ElecTra delivers a comprehensive electrification strategy to achieve significant improvements in performance and sustainability. 

Our Solution

The solution focuses on removing rare earth materials from the process, improving the recyclability of materials used, and utilising existing manufacturing processes, whilst also increasing efficiency and performance and reducing costs. 

The development of magnet-free motor technology to drive these systems will replace the traditional mechanical and hydraulic systems with a more sustainable option that retains performance needs. In addition to removing magnets from the systems, the use of the latest wire technology will look to replace copper windings with aluminium to reduce cost and improve recyclability. 

Furthermore, to reduce the environmental impact throughout the manufacturing process, AEM will deliver an innovative design for manufacture, recyclability and re-use to maximise production readiness.

Integration, customization and safety are critical to the agricultural industry. The development of a cost-effective VCU and integration strategy, with existing hardware and software to meet safety standards, will be complemented by flexible “app-based” functionality to support integration with the wider powertrain. An interface enabling a range of apps based on the agricultural sector’s requirements will allow users to optimise efficiency and use precision agriculture analytics for maximum crop yield and quality. 

Keen to learn more? Stay tuned in to find how it’s going.

More about AEM’s off-highway applications: https://advancedelectricmachines.com/applications/off-highway/

ElecTraDownload

Bensport unveils all-electric concept vehicle

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Bensport unveils La Sarthe E concept for pre-order at the London Classic Car Show

  • All-electric La Sarthe E combines elegance, refinement and sustainable zero emissions motoring
  • Bensport partners with UK-based AEM to integrate world’s most sustainable EV motor
  • La Sarthe E is based on a reconditioned period Bentley chassis and featured hand-crafted aluminium bodywork

Producer of one the world’s most exquisite coach-built Bentleys, Bensport, has today unveiled its all-electric La Sarthe E concept. The marque’s first zero emissions creation will be available to pre-order from 25 June, when Bensport attends the London Classic Car Show.

As well as being zero emissions, Bensport was also determined to ensure the La Sarthe E is as sustainable as possible. As a result, it has partnered with UK-based EV motor manufacturer Advanced Electric Machines (AEM), to integrate its pioneering technology. AEM’s motors do not use rare earth materials, removing the need for harmful mining practices and aiding recyclability. This, coupled with a 54kWh battery pack delivers a refined and responsive driving experience, befitting to a vehicle of its calibre. It is expected that the La Sarthe E will be capable of achieving a total range of around 200 miles.

As is the case with Bensport’s 4.5-litre petrol-fuelled straight-six La Sarthe, the La Sarthe E is built upon an original Bentley Mk6 or R-type chassis, which is meticulously reconditioned. Similarly, the La Sarthe E’s sculpted all-aluminium bodyshell is produced in-house by Bensport’s highly skilled craftspeople. Its expertly trimmed interior uses the highest quality leather and offers customers considerable opportunities to customise dashboard layout, veneer types and colour palettes.

Bob Perry, Managing Director of Bensport, said: “When we created the La Sarthe we wanted it to optimise elegance, refinement and dynamism.  Our La Sarthe E takes this ethos to a new level, offering an almost silent drive, while also drawing our focus to sustainability. We’re delighted to be working with AEM to integrate what we believe to be the world’s most sustainable electric motor in the La Sarthe E as a statement of our intent.”

The Bensport La Sarthe E is available to pre-order from 25 June 2021 by visiting www.bensportltd.co.uk.

About Bensport

With combined Rolls-Royce and Bentley experience totalling more than 100 years, Bensport has distilled its considerable knowledge into producing the La Sarthe. Featuring a coach-built aluminium body designed and produced in-house by Bensport, the La Sarthe is based upon a comprehensively reconditioned Bentley Mk6 or R-Type chassis.

Located in Ilton, Somerset, Bensport employs a small but highly skilled team of expert craftspeople, enabling it to complete all body, mechanical and trim work in house.

Our Growing Team has Doubled in 2020

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2020 is a year to remember for many reasons, and here at Advanced Electric Machines we are celebrating it as the year our team grew from 16 to 32 people.

Everything we have achieved this year – from our first export to our partnership with Bentley and so much more – has been a result of the hard work and talent of our incredible team.

This is only the start of our journey and we are excited for even bigger and better things in 2021, so watch this space…

AEM passes its first ISO 9001:2015 surveillance audit

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We are very pleased to announce, that last week we successfully passed our first ISO 9001:2015 surveillance audit.

After a year of immense challenges, we are incredibly proud to see our commitment to quality and continuous improvement continuing to drive the growth and success of Advanced Electric Machines.

Our team works extremely hard to achieve the high standards we set for ourselves, and as we go from strength to strength, we are excited to see what comes next.

AEM welcomes its first Apprentice

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As the academic year gets underway our COO Mike O’Neill (on the right) is delighted to welcome our first apprentice George Cram (centre) to the business. George will be studying at Sunderland College and will be joined by Jonathan Cook (left) one of our existing employees who this year is starting an HNC in engineering.

George said “ It’s a great opportunity. When I heard about AEM it sounded like a great company to get involved with and work around top class engineers,… it’s exciting to be the first apprentice of AEM”. Jonathan, who has been with us for 2 years said “ I’m really excited about starting my HNC, it’s great that AEM are supporting me to study at Sunderland College who have a great engineering facility”

AEM have been working closely with Sunderland College to provide opportunities for an apprentice and are looking forward, as the business continues to grow to build on this relationship and offer more positions in the future.

Bentley Motors Partnership

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Today, our partners Bentley Motors, have released a press release describing the next stage in bringing SSRD to market (https://www.bentleymedia.com/en/newsitem/1128-bentley-motors-looks-to-the-future-of-electric-drive). 

OCTOPUS, an Innovate UK funded 3 year programme to industrialise the design developed during APEX, brings together the best UK science and engineering facilities with a team of highly innovative UK SMEs to deliver the ultimate EV powertrain system. 

The team involved in the programme will use Diamond Light Source, the UKs most powerful x-ray source to peer inside the motor as it spins at up to 30,000 rpm while at the Hartree Centre in Daresbury we’ll be utilising Europe’s most powerful supercomputer available to industry to model all the details of the motor, power electronics and transmission system as they operate in harmony. 

Partners at the University of Bath and University of Nottingham are supporting with the latest thinking in test and simulation while Hieta, Talga and FD Sims are utilising the latest materials and manufacturing techniques to deliver even lower weight and higher performance. TTPi are continuing the work started in APEX to deliver an integrated power electronics system and of course we at AEMR are working to deliver even more efficiency and torque from our already market leading motor! 

As we move closer to production Bentley are now working to make sure we meet all of the test and validation points necessary for us to get ready for market and continue to set the bar really high in terms of power, torque and, of course, refinement!

It’s great to be on to phase 2 of the programme now and we hope we can continue the success of the APEX programme in delivering performance and innovation into what we believe to be the most sustainable motor technology in the world!