GKN Automotive, a global drive systems company, has joined a new 4 million euro European R&D project — named
HEFT and launched by Spain’s Mondragon University — that aims to develop lower-cost more-efficient permanent-magnet eMotors with increased power density for mass-produced next-generation electric vehicles (EVs). Moreover, these eMotors will include ‘innovations’ relating to configuration and materials that will be validated on two variants of the motor.
These innovations will allow magnets in the eMotor to be smaller in size, contain less rare-earth material, and be eligible for re-use and recycling; and compared to two main reference eMotors already on the market, the final eMotor will offer up to a 20% reduction in power losses, a 28% reduction in production costs, and a reduction in material use of up to 66%.
Furthermore, a long-term circular strategy for ‘rare-earth critical raw materials’ will see the targeting of a reduction in the use of two key rare-earth materials — neodymium and dysprosium — of up to 80%, and the recycling of more than 80% of any rare-earth material used. This strategy is intended to conserve resources and create increased resilience in the European supply chain.
The project is funded by the European Commission and includes a total of eight partners from Belgium, Italy, Slovenia, Spain and the UK. GKN Automotive joins as a key industrial partner, assuming responsibility for manufacturing and assembly, and ensuring the final eMotor design meets industry needs and requirements. Other partners in the consortium are Magneti Ljubljana, Vyncolit, Ikerlan, the University of Nottingham, the University of Bologna and KU Leuven.
Aitor Tovar, GKN Automotive’s senior global manager eMotor development (pictured), said: “The HEFT project is an exciting opportunity to develop the next generation of eMotors that will be more sustainable and efficient while costing less to manufacture. I believe development in these areas is key to the future of electric mobility so I’m delighted that we can contribute our expertise in eDrive innovation as an industrial partner, helping to meet an industry need.”
All the work from GKN Automotive will be carried out from its facility in Zumaia, Spain.