The Development of Synchronous Motor Using Non-Rare Earth Permanent Magnet to Improve Environmental and Economic Sustainability

Abstract

In electric vehicles, permanent magnet synchronous motors (PMSMs) are widely used due to their high torque and efficiency. They commonly use rare earth materials, neodymium, as permanent magnets. These come with high costs and environmental impacts from their production processes. This research aims to design PMSM motors by replacing neodymium magnets with non-rare earth materials, manganese-bismuth (MnBi) and ferrite. Firstly, the requirements torque, and rotational speed of the motor were calculated under extreme conditions for carry loads of 2.5 tons. Next, the ANSYS MotorCAD software was used to adjust the motor including replacing the neodymium with MnBi and ferrite, followed by changing the magnet embedding pattern, increasing the magnets size, and increasing the overall motor size. Finally, two models were selected to compare with the neodymium motor. The results showed that the motors, using MnBi magnets, could provide torque more than ferrite. They achieved the requirements by using delta shaped as magnets embedded pattern and increasing the overall motor size, while providing lower cost and carbon emissions than the original. In conclusion, the PMSM motors, using MnBi magnets, can be sustainable to use in electric vehicles. Its potential can reduce reliance on rare-earth minerals while still meeting practical performance requirements.