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Elon Musk LAUNCHES next-generation EV Propulsion System For 2024.
Future iterations of Tesla electric engines won’t contain any rare earth elements, the company announced at its annual investor conference in March 2023. It could mark a big shift in the design and sustainability of electric motors, given Tesla’s enormous market share in the EV (electric vehicle) industry. And so, recently, Tesla just disclosed its next generation electric motor. What could this be? Let’s find out in today’s episode!
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Early Tesla models, such as the original Model S and X, utilized induction motors, in which the rotor (the revolving portion of the motor) is enclosed in a copper or aluminum cage. With the introduction of the Model 3 in 2017, the use of a permanent magnet (PM) motor was implemented. With a PM motor, a magnetic field is created on the rotor using powerful magnets. The change to a PM design allowed for more efficiency and power density while still using an induction motor as its secondary drive unit (which provides boosts of acceleration when necessary). In 2022, PM motors would account for more than 80% of the market for EV motors, according to IDTechEx research.
The use of rare earths, specifically, in the manufacture of the magnets, is a drawback of PM motors. This category consists of expensive materials with a limited supply chain, such as neodymium and dysprosium. Since China produces the largest majority of the world’s goods, there has previously been price volatility. In 2011, China imposed export restrictions on rare earths, which resulted in a roughly 750% and 2000% price increase for neodymium and dysprosium, respectively.
BMW and Renault used a brushless rotor arrangement, whereas some manufacturers, including Audi and Mercedes, employed induction motors to allay PM worries. However, significant progress has been made to reduce these drawbacks. These designs are often heavier and less effective overall. However, it is still a PM motor, despite Tesla’s claims that their new motor will be rare earth free. PM motors’ rare earth content, notably the heavier rare earths, has been steadily decreased by some manufacturers, including Tesla. However, substitute magnetic materials such as magnets based on ferrite or other alloys are needed if they are to be rare earth-free. These often have magnetic fields that are far weaker, which results in motors that are less power-dense.
There are a few approaches Tesla could have used to make this switch, but it was probably a combination of advancements in magnetic alloys to increase field strength and expanding the motor to provide similar outputs while suffering a loss in power density, as drivers won’t notice unless it affects performance or cargo space.
The specifics of the new design and the materials employed won’t be known to us until a later time, but it will be interesting to see whether (and to what extent) the other of the EV market adopts it. If other automakers follow Tesla’s lead, there may be a significant change in the industry toward more environmentally friendly and less price-sensitive alternatives to rare earth magnets. Tesla’s decision to stop using rare earths alone may have an impact on overall demand.
Although it was not mentioned on Investor Day, we anticipate that ferrite, a well-established concept will most likely replace NdFeB in Tesla’s next-generation motor design.
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