Replacing copper and REE with aluminium proves beneficial for e-motors

A Newcastle-based electric motor (e-motor) manufacturing company, Advanced Electric Machines (AEM), has announced the replacement of copper and rare earth elements with aluminium in their products owing to the latter's cost and energy efficiency.

Image Source: https://www.electricmotorengineering.com/

"Dependence on rare earth elements and copper brings significant political and financial challenges and harms the environment," a convinced CEO and co-founder James Widmer conveyed. "By replacing copper with aluminium, coil costs could be reduced by 89 per cent, and performance increased by up to 30 per cent. This technology redefines how motors are manufactured, recycled, and integrated into sustainable mobility solutions," he added.

AEM, which was founded in 2017, strives to alter the way traditional electromobility has been working to date by using aluminium instead of copper and going with a design that is absolutely free of rare earths. The startup, which surfaced from Newcastle University, ensures lower costs, enhanced performance, and an altogether green (recyclable) technology.

Unlike traditional electric motors, which depend on neodymium or dysprosium magnets, AEM offers an alternative technology that reduces dependence on rare earths and their environmentally damaging extraction.

"By eliminating permanent magnets, we have removed the effects of demagnetisation, making the e-drives safer and reducing the complexity of thermal management," describes Tom Elliott, Business Development Director at AEM, a technical advantage of the approach.

The present series that uses HDSRM (High-Density Switched Reluctance Motor) is a lighter, more sustainable and efficient aluminium-inclusive motor. It reduces power loss by 22 per cent and provides 30 per cent more continuous power, making it energy-efficient.

The motor has no magnetic losses, allowing for higher efficiency at high speeds, can function with standard three-phase inverters and is versatile in use. It operates smoothly even at high temperatures, with nada risk of demagnetisation.

AEM has already tested the HDSRM model for over three million kilometres in real-world conditions. The technology is being used in trucks, buses, and trains. Now, the company is working on a new version of motors for cars and small vehicles called the SSR, which is still in the early stages of development.

The SSRD motor can run at speeds of up to 30,000 revolutions per minute and is 94 per cent efficient. AEM engineers are also working on special electronics that will be integrated into the motor.