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Tag: Electric vehicles
Circular economy: Magnets from old hard drives could wind up in EV motors
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Axial motor with recycled rare-earth material – ORNL
As some of the world’s largest automakers ramp up production for a generation of electric vehicles, the supply of one of the most important ingredients—rare-earth elements—is surely a cause for concern.
Rare-earth elements—especially neodymium—are in short supply because of their limited production locations, much of them in China. They're needed for the compact, power-dense permanent-magnet motors in many of today's EVs, and increasingly for green-energy sector uses like wind farms.
Now, researchers at Oak Ridge National Laboratories are experimenting with mining one of our best sources of rare-earth materials—used computer hard drives—for what can be repurposed in an axial gap motor, a type of permanent-magnet synchronous motor that could be used in electric vehicles or industrial machinery.
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It’s just a demonstration so far, but it shows how magnets from devices that are otherwise destroyed could be recycled and reused as part of a circular economy.
Efforts to reduce rare-earth element use, as well as efforts to reuse and recover rare-earths, are frequently mentioned in sustainability reports. Toyota recently announced a way of cutting the neodymium in motor magnets by 20 percent (or up to 50 percent eventually) by substituting cerium and lanthanum, rare-earths that are processed simultaneously but aren’t as high-demand. And Nissan has, with its e-Power hybrid system slated for more models soon, boasted that it’s cut rare-earth elements by 70 percent.
READ MORE: Limits On Rare-Earth Metals To End After China Loses Global Trade Case
Meanwhile, the appetite for rare-earth elements isn’t showing any signs of cooling. While Tesla went with AC induction motors for its Model S and Model X, it’s moved to a permanent-magnet design to power the rear wheels of the Tesla Model 3. Dual-motor all-wheel-drive versions of the Model 3 get an AC induction motor at the front that’s free of additional rare-earths. Likewise, Volkswagen has said that it’s planning to use permanent-magnet motors for rear motors in millions of new-generation electric vehicles arriving in the U.S. starting in 2020. Audi stands as an outlier, as at both axles it’s using a current-excited synchronous motor design that needs no rare-earths.
Volkswagen MEB platform architecture
The supply pinch is nothing new. Two decades ago, the U.S. was a significant producer of rare-earth elements, as was Australia. Eventually China inched into the market and corporations went out of business as they couldn’t match the prices on the Chinese-sourced material. That’s left China with an uncomfortable monopoly on the world’s supply, especially as the electronics and automotive sectors have been increasingly dependent on these materials.
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The fragility of the situation was demonstrated in 2011 when China cut off supply of rare-earth elements after a political tiff with Japan. Prices skyrocketed, sending users rushing to stockpile the materials initially, before prices tanked and set off some vicious volatility in recent years.
The researchers say that by simply recycling the 35 percent of hard drives that currently are destroyed, about 1,000 metric tons of magnet material could be recovered per year. While they made no statement about how many vehicle motor magnets that might support, every little bit will surely help.
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Electric cars are clean, but can they be profitable? New report casts doubt
Volkswagen MEB platform architecture
A flood of new electric-car models is washing into the market in the next year as automakers scramble to meet regulatory demands for electric cars around the world—not to mention scrambling to compete with Tesla.
The challenge, as with Tesla, is whether they can sell those cars at a profit.
A new report by AlixPartners, a worldwide business consulting firm, shows the transition to electric cars is coming at a steep cost to automakers.
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The company pegs the cost of building new electric cars at almost $9,000 more than conventional cars, and plug-in hybrids at an additional $5,700.
Worldwide, the report says, established and startup automakers are spending $255 billion to develop more than 200 new electric models that are expected to hit the market by 2022.
Many of these will be low-volume models that will not make a significant dent in the development costs for new powertrains, the report says.
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Further, the number of new models is likely to exceed customer demand, the report says, meaning that intense competition among these new electric cars may force automakers to sell them at a discount. This hit to automaker profits could be exacerbated by ride-sharing and autonomous car fleets, which would buy cars at fleet prices.
As if to confirm the report, BMW cheif executive Bernhard Kuhnt told Bloomberg Friday, “Tesla is now ramping up their volumes, and it’s putting pressure on that market segment.”
At the same time, the study notes, the overall car market in the U.S. is beginning a cyclical downturn from its record sales of 17.2 million new cars and trucks in 2017.
That's not to say the study expects electric cars to be unsuccessful. AlixPartners forecasts that by 2030, electric cars will make up 20 percent of the U.S. market, 30 percent of European car sales, and 35 percent of car sales in China.
2020 Mercedes-Benz EQC
In a consumer survey conducted as part of the study, AlixPartners found that 22.5 percent of Americans say they plan for their next car purchase to have plug-in capability.
A Reuters report on the study notes that auto executives generally concur that the transition to electric cars will be expensive, and that R&D and development costs for electrics may not be paid off any time soon. “What everyone needs to realize is that clean mobility is like organic food—it’s more expensive,” Carlos Tavares, chief executive of Peugeot, Citroen, and Opel manufacturer PSA told Reuters.
Last month, BMW warned investors that investments in electric-car development and meeting cleaner emissions rules would erode profits. Volkswagen and Mercedes-Benz also each warned separately that developing electric cars will cost more than they initially budgeted.
So far tax incentives from many governments, such as the U.S. federal $7,500 tax credit, are designed to offset these higher costs. As automakers begin to sell millions of electric cars, however, these tax incentives may become unsustainable.
READ MORE: 2020 Mercedes-Benz EQC specs revealed (Updated)
The hope is that by then battery prices will equal the cost of internal combustion powertrains, but that's not guaranteed. Batteries currently account for 40 percent of the cost of building an electric car, Reuters reports.
AlixPartners reports that commodity costs are up 70 percent the last year compared with 2015, at $884 per car, a six-year high.
“Industry players are sort of caught between a rock and a hard place,” said Shiv Shivaraman, co-head of AlixPartners' American automotive and industrial practice. “If they don’t participate in some way in the ‘new-mobility’ revolution that’s coming, they stand to lose out on what might be the biggest thing ever in this industry. If they do participate, as so many are, they have the chance of benefiting from first-mover advantages, but they also face the possibility of going broke in the process.”
One size won’t fit all for future Kia EVs
2019 Kia Niro EV
For an automaker that’s pitching itself toward the fun side of the Hyundai Motor Group, the tone for the automaker’s sizable electric push soon sounds altogether like pants.
“It’s all about what fits,” said Michael Winkler, director of powertrains for Kia in Europe.
By the end of next year, Kia will offer in the U.S. all-electric versions of both the boxy Soul and the hatchback Niro.
Neither have been officially confirmed by the automaker: the next-gen Soul is still in development, and the Niro EV just made its debut for Europe with no word for a version in the U.S. Confirmation of both for buyers in the U.S. is just a formality.
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The specs for the Niro EV are all but set for the U.S.: 64-kwh battery, 201 horsepower, more than 240 miles of range—if not more. Although what the Niro rides atop is shared with the Hyundai Ioniq Electric, it borrows most of its powertrain components, including battery and motor, from the Kona Electric crossover.
When the Soul EV arrives, it’s likely to share its fundamental layout with the Kona Electric, although its powertrain configuration is less clear.
2020 Kia Niro EV, 2018 Paris auto show
It’s unlikely to get the same 64-kwh battery as the Niro EV, and instead may receive a 39-kwh battery from the European and Korean version of the Niro. If the Soul EV is a funky, urban green car, the Niro EV will be the big, electric family car.
Kia seems content to offer two electric vehicles in their portfolio—at least two—that fit different sizes.
The Niro EV and Ioniq Electric are related, both built on the same corporate platform, and the Ioniq’s paltry 124-mile range could be collaterally improved by the mere existence of the Niro EV. (The Ioniq’s pack is merely 29 kwh and upgrades to the 39-kwh pack, at the very least, does seem like a natural fit.)
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Kia hasn’t yet developed its own electric powertrain separate from Hyundai, and it’s unlikely that the two automakers will keep anything from each other anytime soon. Batteries, which are sourced from LG Chem, likely will be shared between the two makes, and the models share similar drive motors.
For now, engineers consider electrified vehicles to be one line of a multifaceted approach to propulsion. Gas, diesel, 48-volt mild hybrid, hybrid, plug-in hybrid, EV, and fuel-cell powertrains are all on Kia’s menu around the world.
“It’s just a question of where the products will go,” said Winkler.
EV sales percentages are single-digit for nearly all markets. In the U.S. it’s around 1 percent and in France it’s just about 2 percent—although there are anomalies such as Norway, where EV sales add up to more than a third of the new-car market. Friendly regulations toward electrified powertrains (and unfriendly policies for diesel) may vault EV demand in the short term to keep Kia scrambling to satisfy the rush.
2018 Kia Niro Plug-in Hybrid
Winkel is eager to temper that kind of enthusiasm with the reality that EVs may not be suited for every application. Internal combustion may be a better fit for bigger vehicles meant to go long distances for now. EVs may be best suited for city dwellers with sufficient access to charging stations, plug-in hybrids if they don’t. Diesel still figures heavily into the plans for now, although not in the U.S.
Europe and America seem ripe for multiple electric models from the same automaker, and it seems fairly certain to predict a rising demand.
“All I know about forecasting is, it will be wrong,” Winkler said.
Mercedes-Benz starts construction for battery factory next to U.S. vehicle plant
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