Researchers have developed a new multi-flux barrier interior permanent magnet (IPM) motor design that significantly reduces reliance on rare-earth materials. This breakthrough is crucial for the electric vehicle industry, which currently heavily depends on these scarce and expensive materials. The new motor combines low-cost ferrite magnets with a reduced amount of neodymium magnets, achieving a balance between performance and sustainability.

The proposed design, termed a hybrid-magnet multi-flux barrier IPM motor, optimizes the configuration of magnets and flux barriers to maximize torque density and efficiency. The primary goal is to maintain competitive performance with conventional IPM motors, which use a high proportion of neodymium magnets, while drastically decreasing the amount of this material. This is achieved through an intelligent arrangement that leverages the magnetic properties of both types of magnets.

Reducing rare-earth usage addresses a growing concern in the electric vehicle supply chain. The extraction and processing of neodymium and other rare-earth elements are complex, energy-intensive processes with significant environmental impact. Furthermore, price volatility and geopolitical tensions associated with these materials pose a risk to mass production of electric vehicles. This new design offers a viable alternative to mitigate these challenges, promoting more sustainable and economically stable transport electrification.