Benefits and Applications of Rare-Earth Magnet-Free Electric Machines | EMWORKS, INC.

Introduction

Electric machines are critical components of various industrial applications, including electric vehicles, wind turbines, and industrial automation. As the world shifts towards renewable energy sources, there is a growing demand for high-performance electric machines that can deliver high power density, efficiency, and reliability. One of the key components of electric machines is the permanent magnet, which is typically made of rare-earth metals such as neodymium and dysprosium. However, these metals are expensive and their extraction and processing have significant environmental impacts. In this blog, we will discuss high-performance rare-earth magnet-free electric machines that can provide an environmentally sustainable and cost-effective solution.

Challenges of Rare-Earth Magnet-based Electric Machines

Rare-earth magnet-based electric machines have several advantages, including high power density, efficiency, and torque density. However, the use of rare-earth magnets poses several challenges, including:

• Cost: Rare-earth metals are expensive and their price is highly volatile, which makes it difficult to predict the cost of electric machines.
• Environmental Impact: The extraction and processing of rare-earth metals have significant environmental impacts, including water and soil pollution, land degradation, and greenhouse gas emissions.
• Supply Chain Dependence: China dominates the global production of rare-earth metals, which poses a supply chain risk for countries that depend on these metals for their industries.

Design of Rare-Earth Magnet-Free Electric Machines

To overcome the challenges posed by rare-earth magnet-based electric machines, researchers and engineers have developed several designs of rare-earth magnet-free electric machines. These designs use alternative materials and technologies to achieve high performance and efficiency. Some of the commonly used designs are:

Induction Machines: Induction machines, also known as asynchronous machines, are the most commonly used electric machines in industrial applications. They operate on the principle of electromagnetic induction and do not require permanent magnets. Induction machines are reliable, robust, and cost-effective, making them ideal for various industrial applications.

Synchronous Reluctance Machines: Synchronous reluctance machines are similar to induction machines but have a different rotor design. Instead of permanent magnets, these machines use a rotor with salient poles that align with the stator poles to generate torque. Synchronous reluctance machines have high torque density and efficiency, making them suitable for high-performance applications.

Switched Reluctance Machines: Switched reluctance machines are another type of rare-earth magnet-free electric machine that uses a rotor with salient poles. However, unlike synchronous reluctance machines, the poles are not aligned with the stator poles. Instead, the magnetic field is created by energizing the stator coils in a specific sequence to attract the rotor poles. Switched reluctance machines are highly efficient and reliable but require sophisticated control algorithms.

Permanent Magnet Assisted Synchronous Reluctance Machines: Permanent Magnet Assisted Synchronous Reluctance Machines (PMa-SynRM) are a hybrid design that combines the advantages of permanent magnet machines and synchronous reluctance machines. These machines use a rotor with both permanent magnets and salient poles to achieve high torque density and efficiency. PMa-SynRM machines are ideal for applications that require high power density and reliability.

Advantages of Rare-Earth Magnet-Free Electric Machines

Rare-earth magnet-free electric machines have several advantages over rare-earth magnet-based electric machines, including:

• Cost: Rare-earth magnet-free electric machines are cost-effective and offer a predictable cost structure, making them ideal for large-scale industrial applications.
• Environmental Sustainability: Rare-earth magnet-free electric machines do not require rare-earth metals, which reduces the environmental impact of their production and disposal.
• Reliability: Rare-earth magnet-free electric machines are reliable and require minimal maintenance, making them suitable for applications that require continuous operation.
• Flexibility: Rare-earth magnet-free electric machines can be designedto meet specific performance requirements and can be customized for various industrial applications.

Applications of Rare-Earth Magnet-Free Electric Machines

Rare-earth magnet-free electric machines are suitable for various industrial applications. Rare-earth magnet-free electric machines are ideal for electric vehicles as they offer high power density and efficiency. Induction machines and synchronous reluctance machines are commonly used in electric vehicles due to their reliability and cost-effectiveness.

Wind turbines require electric machines that can operate in harsh environmental conditions and deliver high efficiency. Synchronous reluctance machines and PMa-SynRM machines are suitable for wind turbines as they offer high torque density and reliability. Also, industrial automation requires electric machines that can operate continuously and deliver high performance. Induction machines and synchronous reluctance machines are commonly used in industrial automation due to their reliability and cost-effectiveness.

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Cover picture credit: Lesics [https://www.youtube.com/watch?v=esUb7Zy5Oio]

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