Making EV Motors, And Breaking Up With Rare Earth Elements

July 9, 2024 by Donald Papp 85 Comments

Rare earth elements are used to produce magnets with very high strength that also strongly resist demagnetization, their performance is key to modern motors such as those in electric vehicles (EVs). The stronger the magnets, the lighter and more efficient a motor can be. So what exactly does it take to break up with rare earths?

Rare earth elements (REEs) are actually abundant in the Earth’s crust, technically speaking. The problem is they are found in very low concentrations, and inconveniently mixed with other elements when found. Huge amounts of ore are required to extract useful quantities, which requires substantial industrial processing. The processes involved are ecologically harmful and result in large amounts of toxic waste.

Moving away from rare earth magnets in EV motors would bring a lot of benefits, but poses challenges. There are two basic approaches: optimize a motor for non-rare-earth magnets (such as iron nitrides), or do away with permanent magnets entirely in favor of electromagnets (pictured above). There are significant engineering challenges to both approaches, and it’s difficult to say which will be best in the end. But research and prototypes are making it increasingly clear that effective REE-free motors are perfectly feasible. Breaking up with REEs and their toxic heritage would be much easier when their main benefit — technological performance — gets taken off the table as a unique advantage.

Iron Nitrides: Powerful Magnets Without The Rare Earth Elements

September 1, 2022 by Dan Maloney 41 Comments

Since their relatively recent appearance on the commercial scene, rare-earth magnets have made quite a splash in the public imagination. The amount of magnetic energy packed into these tiny, shiny objects has led to technological leaps that weren’t possible before they came along, like the vibration motors in cell phones, or the tiny speakers in earbuds and hearing aids. And that’s not to mention the motors in electric vehicles and the generators in wind turbines, along with countless medical, military, and scientific uses.

These advances come at a cost, though, as the rare earth elements needed to make them are getting harder to come by. It’s not that rare earth elements like neodymium are all that rare geologically; rather, deposits are unevenly distributed, making it easy for the metals to become pawns in a neverending geopolitical chess game. What’s more, extracting them from their ores is a tricky business in an era of increased sensitivity to environmental considerations.

Luckily, there’s more than one way to make a magnet, and it may soon be possible to build permanent magnets as strong as neodymium magnets, but without any rare earth metals. In fact, the only thing needed to make them is iron and nitrogen, plus an understanding of crystal structure and some engineering ingenuity.

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Recycling Will Be Key To The Electric Vehicle Future

July 15, 2021 by Lewin Day 113 Comments

Electric vehicles have become a mainstay in the global automotive marketplace, taking on their gasoline rivals and steadily chewing out their own slice of market share, year after year. Government mandates to end the sale of polluting internal combustion engine vehicles and subsidies on cleaner cars promise to conspire to create an electric vehicle boom.

The result should be much cleaner air, as generating electricity in even the dirtiest power plants is far cleaner and more efficient than millions of individual engines puttering about the place. However, if the electric car is to reign supreme, they’ll need to be built in ever greater numbers. To do that is going to take huge amounts of certain materials that can be expensive and sometimes in very limited supply. Thus, to help support the EV boom, recycling of these materials may come to play a very important role.

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Jigsaw Motor Uses PCB Coils For Radial Flux

July 16, 2019 by Dan Maloney 7 Comments

Electric motors are easy to make; remember those experiments with wire-wrapped nails? But what’s easy to make is often hard to engineer, and making a motor that’s small, light, and powerful can be difficult. [Carl Bugeja] however is not one to back down from a challenge, and his tiny “jigsaw” PCB motor is the latest result of his motor-building experiments.

We’re used to seeing brushless PCB motors from [Carl], but mainly of the axial-flux variety, wherein the stator coils are arranged so their magnetic lines of force are parallel to the motor’s shaft – his tiny PCB motors are a great example of this geometry. While those can be completely printed, they’re far from optimal. So, [Carl] started looking at ways to make a radial-flux PCB motor. His design has six six-layer PCB coils soldered perpendicular to a hexagonal end plate. The end plate has traces to connect the coils in a star configuration, and together with a matching top plate, they provide support for tiny bearings. The rotor meanwhile is a 3D-printed cube with press-fit neodymium magnets. Check out the build in the video below.

Connected to an ESC, the motor works decently, but not spectacularly. [Carl] admits that more tweaking is in order, and we have little doubt he’ll keep optimizing the design. We like the look of this, and we’re keen to see it improved.

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Rare Earth Metals Caught In Trade War

June 4, 2019 by Dan Maloney 78 Comments

It seems these days that the news is never good. Speaking from experience, that’s really nothing new; there’s always been something to worry about, and world leaders have always been adept at playing the games that inevitably lead to disturbing news. Wars always result in the very worst news, of course, and putting any kind of modifier in front of the word, like “Cold” or “proxy”, does little to ameliorate the impact.

And so the headlines have been filled these last months with stories of trade wars, with the primary belligerents being the United States and China. We’ve covered a bit about how tariffs, which serve as the primary weapons in any trade war, have impacted the supply of electronic components and other materials of importance to hackers.

But now, as the trade war continues, a more serious front is opening up, one that could have serious consequences not just to the parties involved but also to the world at large. The trade war has escalated to include rare earth metals, and if the threats and rumors currently circulating come to fruition, the technologies and industries that make up the very core of modern society will be in danger of grinding to a halt, at least temporarily.

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Give Yourself A Sixth Sense On The Cheap

January 2, 2012 by Mike Nathan 71 Comments

sixth-sense-magnetic-ring

Hackaday regular [Mikey Sklar] is no stranger to body modifications. He enjoys tweaking his body in ways that help him with day to day tasks, including a ruler tattoo on his arm and an RFID chip embedded in the web of his hand. Lately, he has been toying around with a less invasive means of getting a better feel for magnetic fields in his surroundings.

Turned on to magnetic rings by a friend, he now wears an epoxy-coated rare earth ring every day, changing the way he interacts with the world. He says that besides the obvious ability to tell when he’s near iron-heavy material, he can also feel cell phone calls, as the speaker draws the ring closer while producing sound.

He says that holding the electric cord of his tea kettle gave him the biggest start, making him feel as if he had been electrocuted, minus the actual shock.

While it’s not the most high-tech hack, [Mikey] is quite happy with the “sixth sense” this reasonably price ring has been able to provide – we just might have to try it out ourselves.

RC Plane Built Using Pieces Of An RC Car

December 11, 2010 by Mike Szczys 17 Comments

This hack’s old as dirt to be sure, but new to us and a great accomplishment. The plane above, which is meant to fly without an operator, has been given RC control thanks to parts from that little car. The transmitter and receiver pair are the obvious transplant, but how do you add steering to a $7 plane that wasn’t manufactured to have that feature? The tail was cut and reconnected with mylar hinges to turn it into a rudder. A rare earth magnet and a coil are also thrown into the mix to provide movement. Basically this is a simple solenoid where the coil pushes against the magnet when energized, actuating the rudder. This in combination with an upgraded motor allows for both speed control and yaw. It doesn’t look like you can control roll and pitch but what more can you really expect?

This would be a nice first step on that path to building an epic flying camera rig.

[Thanks Rob]