Reducing Rare-Earth Magnet Reliance in Modern Traction Electric Machines

Currently, electric machines predominantly rely on costly rare-earth NdFeB magnets, which pose both economic and environmental challenges due to rising demand. This research explores recent advancements in machine topologies and magnetic materials to identify and assess promising solutions to this issue. The study investigates two alternative machine topologies to the conventional permanent magnet synchronous machine (PMSM): the permanent magnet-assisted synchronous reluctance machine (PMaSynRM), which reduces magnet usage, and the wound-field synchronous machine (WFSM), which eliminates magnets entirely. Additionally, the potential of ferrite and recycled NdFeB magnets as substitutes for primary NdFeB magnets is evaluated. Through detailed simulations, the study compares the performance and cost-effectiveness of these solutions against a reference permanent magnet synchronous machine (PMSM). Given their promising performance characteristics and potential to reduce or eliminate the use of rare-earth materials in next-generation electric machines, it is recommended that future research should focus on novel topologies like hybrid-excitation, axial-flux, and switched reluctance machines with an emphasis on manufacturability and also novel magnetic materials such as FeN and MnBi that are currently seeing synthesis challenges.