As electric vehicles (EVs) become increasingly prevalent, the focus on battery recycling has grown to ensure the sustainability of these eco-friendly vehicles. However, there’s another critical player in this green revolution – the electric motor – and its potential for a second life could be a game-changer.
Prolonging the lifespan of electric motors is vital for two key reasons. Firstly, these motors contain valuable raw materials like copper and rare earth metals such as neodymium, which are challenging to recover through traditional recycling methods. Secondly, the production of motor components leaves a larger carbon footprint compared to conventional combustion engines. Current recycling techniques fall short in addressing these challenges. Recycled materials often end up contaminated and unsuitable for reuse in motor applications, while other motor components are often irreversibly damaged.
To address this issue head-on, researchers at the Fraunhofer Institute for Manufacturing Engineering and Automation IPA have initiated the REASSERT project. “With the REASSERT project, our aim is to establish a closed-loop system that promotes the reuse of valuable resources, reducing dependence on raw material imports and minimizing the environmental impact of raw material extraction,” explained Julian Große Erdmann, a scientist at the institute. With this aim at its core, the project focuses on four value retention strategies: reuse of the entire engine; repair with the replacement of of defective components; remanufacturing, where all components are disassembled, cleaned, conditioned, and reassembled; and raw material recycling by disassembling the motor and sorting the individual materials before shedding.
Process Chain :
The project is set to establish a comprehensive process chain, covering motor classification, disassembly, component diagnosis, reassembly, and end-of-life testing. Each step in this chain will be accompanied by dedicated demonstrators and test rigs. Julian Große Erdmann clarified, “The effort for reconditioning may vary depending on the chosen value preservation strategy, as different process steps and chains are involved.”
To facilitate this intricate process, the team will employ reference motors from the passenger EV segment and harness the power of a specially developed AI tool. This tool will assist in selecting the optimal value retention strategy for each motor, enhancing efficiency and effectiveness. The Ultimate Goal: A Prototype Motor The overarching objective of REASSERT is to develop a prototype motor that seamlessly integrates all four value retention strategies. Success in this endeavor could pave the way for the design of new electric motors that actively contribute to a circular economy.
A Collaborative Effort The REASSERT project is a collaborative endeavor involving five industry partners, with Schaeffler leading the consortium. Partnering organizations include the Karlsruhe Institute of Technology, BRIGHT Testing GmbH, iFAKT GmbH, and Riebesam GmbH & Co. KG. The initiative has garnered support from the German Federal Ministry for Economic Affairs and Climate Action, underlining the significance of its goals in advancing sustainable practices in electric vehicle technology.
Source: The Next Web