Tesla's next-gen electric motors will get rid of rare earth elements
insideevs.com
insideevs.com
If successful, this contributes towards the reduction of national security risk around rare earth supplies and supply chain located in a possibly unfriendly nation state (major deposits are in Russia and China) and also means you don’t have to establish rare earth mines or supply chains in your own countries (capital and environmental concerns). It’s a big deal!
Also, just as newer battery chemistries moved away from cobalt (a conflict mineral), this too is progress in countering arguments against EVs due to their material sourcing.
“Simplicity is the ultimate sophistication.”
Tesla seems to be the leader here. Per Investor Day[0] and other sources, they
- developed low-cobalt and low-nickel cathodes, to reduce scarce battery metals
- increased overall vehicle efficiency to allow iron cathodes which are earth-abundant
- consolidated electronic modules to reduce microchips and wiring
- are soon switching to 48V, to further reduce low-voltage copper wiring (copper being a 'medium-rare' metal)
- switched from copper to aluminum high voltage conductors (per Munro Live), aluminum having better conductivity-to-weight
- reduced vehicle structure with structural battery design and 'gigacasting' manufacturing
Many of these seem to benefit from vertical integration.
Are any other manufacturers pushing as hard here?
Why would they. Most of those things are not sustainable.
You don't want alluminium wires in your car.
Where aluminum causes fires is due to the fact that it expands and contracts more than copper does, and it can oxidize and corrode when not properly cared for (for example, when dissimilar metals are used, or when exposed aluminum wire ends are not properly coated).
We can assume that someone at Tesla is familiar with the properties of aluminum and can insure that they are using the right connectors to mitigate these issues. (or at least, we can hope)
Aluminum was used for a short time in the west for household wiring and was quickly outlawed.
Edit: Judging by the picture on this article [1] I am wrong.
[1]: https://hackaday.com/2022/01/13/exploring-tesla-model-s-high...
Why not? I^2*r says that running 75% less current will generate 94% less heat.
Existing copper wires would be a disaster if cars ran on a 3V system. Aluminum at 48V will be fine, as long as it’s sized appropriately the same way copper is today.
Thats not the argument, you can do that now with copper cables.
Aluminium is a good conductor, but it is reactive, brittle and not as malleable as copper.
also, copper has almost half the resistance per meter than aluminium. So even for solid bus bars, it doesn't make that much sense, unless you have structural bus bars.
But 4 times the weight
And twice the resistance doesn’t matter. So you go one gauge bigger. If the material is cheaper, more available, and suitable, that’s fine. We don’t insist on gold wires because they’re “better” than copper.
It’s all tradeoffs. I don’t see a reason to be philosophically opposed to aluminum other than “it’s possible to do it wrong”, which is of course also true for copper.
Indeed, but automotive wiring is subject to intense and persistent vibration and heat cycles. so all those ties become stress points for fatigue to cluster around.
I'm not saying its never a good idea to use an aluminium wire loom, but I'm struggling to find a situation where its required
The place Tesla used this was for fixed rigid bus bars, notably the "cable" from the charge port to the battery.[0]
Previously they used traditional stranded copper. Now it's a solid aluminum conductor, wrapped in insulation and protected by an outer aluminum tube.
These are thick high voltage conductors. I'm sure Tesla did their homework on flex and fatigue.
As for resistance, this is why I mentioned conductivity-to-weight as being the critical metric. Copper is over 3x as dense, at 9.0 g/cm³ vs 2.7 g/cm³ for aluminum. It doesn't hurt that aluminum is cheaper and more abundant.
Additionally, aircraft airframes are regularly inspected and fully radiographed at certain intervals. Components that develop flaws are changed out when the flaws are detected. The same is not true of cars.
Why not?
If Tesla has switched to aluminum I imagine they've found a way to fix that. Possibly by making the entire electrical system out of aluminum, so that it all expands the same way, or possibly a connector designed to avoid that.
Properly terminated, there is no problem with aluminum wiring in your house. As another replier mentioned, most houses do have aluminum wiring in the run to the house and the run from the meter to the panel, and sometimes in the larger runs like stove and dryer.
It's also worth noting that the newer aluminum formulas like Southwire SIMpul, are not like the old aluminum like was installed in my house in the early '70s. But, buyers are still gunshy from the '70s, so copper is generally preferred
I think that everyone should look on his "forward looking statements" with a higher than normal degree of skepticism. He does seem to pull off a lot of outlandish stuff, though, so it doesn't pay to be too skeptical.
> I consider him and his companies to be completely untrustworthy. He could be selling water in the desert and I still would never buy another thing from him.
I don't think that that same level of skepticism is warranted towards his statements about what is true today. But then again, I haven't been following him very closely, so maybe his pant are constantly on fire.
https://twitter.com/ICannot_Enough/status/161837414087616512...
This is about as silly as people who think he’s the messiah. He’s clearly over promised on many things, but he’s also delivered on a lot.
And spacex motto is turning the impossible into late, so he’s being pretty honest about his goals being off. What’s the issue? Why do you hate him so much?
In an interview by Munro[1] , Elon Musk previously mentioned the desire to switch to 48V together with the desire to use PoE. Combining data and power over the same wires.
The move of automakers to 48V has been in the works for a while:
* https://www.autoevolution.com/news/understanding-the-shift-t...
* https://whma.org/overview-of-48-volt-systems-in-the-automoti...
* https://www.google.com/search?q=48V+cars
It's just a bit of a co-ordination / chicken-egg problem in that equipment probably has to be to handle 12V and 48V for a while during a transition period.
They’re also in-sourcing electronics which should help give Tesla greater supply chain control.
Plus the non-rare-earth high energy permanent magnets thing is a pretty huge blow to China’s efforts to monopolize the rare earth magnet supply chain. China produces 92% of the rare earth magnets in the world, as well as mining the vast majority of the material and also processing.
Tesla doesn’t want to cut off China. But having less reliance on China helps prevent Tesla from being manipulated by the whims of Chinese government leadership, increasing Tesla’s bargaining power in China.
So this isn't really anything to do with national security. It's a better moral outcome with some economic trade off...
If China were to stop selling them, everyone else would have a lot of difficulties replacing them right away and would need at least 5-10 years to pick up the pace.
My understanding is that both China and Russia underpriced on purpose, driving (for example) US mines and production out of business.
And after, then raised pricing.
There are many rare earth mines in North America, sitting fallow...
(This isn't an unknown business tactic for anyone to follow.)
It is most certainly a trade off and I'm not seeing where the cons are mentioned.
Moreover, lithium-ion batteries have by far the most efficienty energy density, so what is tesla getting rid of, most certainly not lithium, which is the bulk of the battery.
Iron nitride magnets are probably the most likely candidate, and they can actually have higher energy than rare earth magnets, and have particularly good high temperature coercivity compared to Neodymium based magnets, although not quite as high coercivity at room temperatures (but high temperature may be the limiting factor in existing motors).
So I don’t understand where this sad sack negativity comes from, because it most certainly doesn’t come from knowledge in the field. There are materials science improvements over time, and this is one such area. There can be a net improvement, not just a pure trade-off. Niron Magnetics is one such company trying to commercialize the material, and you can go to their location in Minneapolis and play with their iron nitride magnets if you like.
Tesla did use high energy cylindrical li-ion cells in their cars before others. Sometimes things improve, through the hard work of researchers.
Disclaimer: I am no fanboy of Tesla; I think Tesla's lunch will be eaten by BYD, either alone or together with other Chinese EV manufacturers, in part because Tesla has been resting on its laurels for so long (still selling the model S!); but facts are facts.
> But battery research is ongoing from a century...
Tesla's claim is about motors, not batteries.
Tesla has implemented solutions that no one else has, such as their "two casting chassis", which Toyota engineers recently called " a work of art" and "genius". The 4680 cylindrical battery is also a Tesla innovation.
> It is most certainly a trade off...
It is not clear at all whether this announced motor is a trade off. It may be the way ahead to further improvements in the space of EV motors. More detail would be good to have; that much is true.
> Moreover, lithium-ion batteries...[lithium] is the bulk of the battery.
Again, this is about motors, not batteries. It's eliminating the neodymium and other "rare earth"[1] elements used in the permanent magnets present in nearly all EV motors to date. No EV motors use lithium in significant amounts.
But the numeracy nazi in me must also point out that when it comes to batteries, there is more nickel than lithium, by a considerable margin, in NMC and NCA (nickel-manganese-cobalt and nickel-cobalt-aluminum) lithium-ion batteries. There is more iron than lithium in LFP lithium batteries. And depending on construction, there may be still more copper.
1. "Earth" is a now-obsolete term for "ore". These metals are not rare, but they spread themselves around, so economically minable ore bodies tend to be hard to find. The metals are not rare, but their earths are.
The tech and featues in a Tesla are far beyond what BYD is even close to delivering.
BYD's growth has been nothing close to Tesla's
Tesla has around four times the net income of BYD despite BYD selling three times as many cars
Telsa is making industry defining changes to manufacturing that BYD hasn't even started on
Telsa is deploying more than double the battery capacity as BYD
Tesla is far more vertically integrated than BYD
Not sure how any of this is resting on laurels or at all a sign that BYD is at risk of being a threat
BMW already has a motor that doesn't use rare earths:
https://interestingengineering.com/innovation/bmws-fifth-gen...
https://www.motortrend.com/news/bmw-ix-m60-brushed-electric-...
> "Manganese-based permanent magnetic materials have become an area of significant research activity in recent years as a potential alternative to permanent magnets based on Rare Earth (RE) metals. Manganese compounds are capable of achieving a relatively high energy product, BH, when processed to have a strong texture. Research has identified three promising compounds for Mn-based permanent magnets: Mn-Ga, Mn-Bi, and Mn-Al. While calculations show that these compounds cannot achieve the theoretical maximum energy products, (BH)max, of RE magnets, current research suggests than they can fill the property gap between inexpensive, but low-performance, ferrites and expensive high-performance RE magnets."
"Manganese-based permanent magnet materials" (2022) T Keller, I Baker - Progress in Materials Science
If you're going to make an article about electric motors in Teslas, at least make sure you get the facts about the electric motors right.
> Tesla announced at its 2024 Investor Day event that it plans to bring...
>The Model 3 does use a permanent magnet motor, but it's an AC synchronous reluctance motor.
No, synchronous reluctance motors do not use permanent magnets on their rotors. The motors that do are called "brushless DC motors". I'm not sure what the Model 3 uses, but last time I saw a cutaway, years ago, it was using an inductance motor, which is entirely different, but maybe they switched to BLDC for efficiency gains.
the power is probably MVDC from the large battery. And these are large xxMW motors.
So will we end up usong inverters anyway?
There aren't many ways to make permanent magnet motors without rare earths. The slide specifically claims this is the next generation permanent magnet motor.
So the question is... Did they invent a new magnet Chemistry... Or are they using a known magnet Chemistry and are okay with not-very-strong magnets?
https://www.nironmagnetics.com/
https://hackaday.com/2022/09/01/iron-nitrides-powerful-magne...
So it sounds like they haven't yet figured out how to make a magnet as strong as a regular NeFeB magnet, but it is theoretically possible to do so.
Magnet strength is one of the key inputs for motor torque per unit mass, and it seems unlikely Tesla would want to trade off much of either mass or torque for price.
See the recent chip crisis.
Tesla routinely make this tradeoff -- e.g. the Standard Range M3 uses LFP (litium iron phosphate) batteries that are cheaper but less energy dense compared the to Long Range M3 that uses a more nickel-based lithium battery that's more performant.
New content for https://elonmusk.today
https://electrek.co/2022/08/05/tesla-model-y-on-track-worlds...
I think Elon Musk does a lot of very good things, but I do think he often is stupid, a liar, and at worst a useful idiot. In the end though, SpaceX, Starlink & Tesla have all been net positives for humanity. Jobs and Gates both were/are not great people, but their products and companies have been good for basically everyone, so it's not a new concept.
But for a while, you had to get a Tesla to get a pure EV. The real question is, as competitors come online, are people likely to purchase another Tesla or try something new?
My sample doesn't have to be random, 10 years ago I could go to a large wealthy city in Europe and only see European cars. Again, that is/was the norm. You would not see Toyotas or Fords, etc. Tesla has been made into an exception. So far the only European brand that even has an EV that can compare with Tesla's is Porche and it's 2x the price. If I'm not mistaken Tesla is now Norway's number one make, which seems like a big deal.
This could change, but I don't see it changing anytime soon given how bad some of the competition is. I was excited about the EV F150 but it too has shown they are still very far behind. Still don't think Telsa should be worth more than every major automaker combined. I'm not arguing anyone should buy their stock.
(And no I’m not confusing it for fjords in Norway)
I'm sorry, but this is just completely false. Both car brands are extremely popular in most parts of Europe, not sure where you've been...
Teslas are also popular, no doubt about it. They have some advantages (for example, the charging network) compared to others, we'll see how long it will last. As opposed to the US, the main EU high-speed charging network competitor (called Ionity) is actually getting close to full coverage in most EU countries (except for Greece, for some reason), and is of similar quality, albeit a bit more expensive.
Extremely popular? I don't think so. 7% of market share is not "extremely popular." I've been in most every country in Europe and barely ever see any Fords, Chevys or Toyotas. Maybe some commercial vehicles for Ford, but rarely a car/SUV/truck. Most every car is a European brand or a sub-brand. Tesla doesn't have much share but is already at around 2%, however Tesla's Model Y was the top selling model in Europe last year. When I go to Europe now it's hard not to spot them because they make up such a significant portion of new car sales there. The most popular Ford (Kuga) was outsold ~6x by the Model Y, the most popular Toyota (Yaris) was outside ~2x by the Model Y. That's pretty significant given Ford and Toyota have been in Europe for a long time. Maybe you're conflating the UK with the rest of Europe, where Ford is more popular, I'm mostly referring to the mainland.
Norway's population is a fraction of USA's, so of course USA will have the raw numbers.
However, Norway's new car BEV % is 80%. The remainder is split between hybrids and pure fossil.
I drove the length of the country so don't think this was a sampling problem.
Maybe because in Europe you have other auto makers that make electric and non electric versions of the same car so you just assume they aren't EV? The Hyundai Kona is basically the same outside except for the front grille and no exhaust. Unless you know that, you don't really know the difference. I would say (in Portugal) on my daily drives I identify around 6/7 Evs for every Tesla. And as I said, I probably missed some as I can't distinguish them
[1] https://alternative-fuels-observatory.ec.europa.eu/general-i... (oct 2022, first data I found but there is also anual)
I love how Tesla fans are so quick to applaud how much money Tesla is making from them. It seems most of "the mission" is (re-) building Musk's wealth.
> such as their heat pumps
The heat pumps that have been a problematic nightmare?
;-)
No one ever said Katy Perry had the Bolt or Nissan leaf of tour stages. I recommend some brand equity reading, as well as behavioral economics around the psychology of auto purchases (lots of emotion, brand loyalty, etc).
https://twitter.com/katyperry/status/444228348319784960 (“Omg someone just called my stage the TESLA of tour stages... It was like, the coolest modern compliment ever.”) (2014)
Recalls and multiple software fixes.
They make good gear but I don’t want to put another dollar in that guy’s pocket.
Units sold are units sold, and the total global addressable market for EVs is substantial (60-80 million units/pa, depending on bucketing).
I too have personal opinions, but crucially, one should not extrapolate them out to entire markets without a rigorous examination of observations and data. Put your ear to the ground, otherwise you’ll get trampled.
Forget the total addressable EV market. They can cruise for another decade or more just based on the number of Elon worshippers.
For example: Half the people on this board daily drive phones from the biggest spyware company on earth.
I just don't understand the hate around this company. It's not enough to criticize, people need to deploy stuff like "virtually without meaning", or "will never do it". I mean, can't they just be like any other company that spins a bit with their product announcements?
In this specific case, though, the criticism is just silly. Tesla already deploys induction motors on half the drive train that meet this requirement. The question is whether they can get rid of the (higher power/weight) permanent magnet motors in the back.
[0] https://twitter.com/elonmusk/status/1380316949087854595?s=20
The letter's "a," "b,", "i," and "t" are doing enough heavy lifting to threaten SpaceX's business model.
But the specific form of this announcement is industry catch-up. Other makes already ship zero-rare-earth motors to the mass market, and Tesla did itself in the past.
Again, I just don't understand the discourse. By the same standards you are using one should never trust criticism of Tesla because it's likely to be phrased as ridiculous cherry-picked hyperbole (e.g. "some other company the guy owns is a moonshot brain thing ergo century-old motor technology will never happen" -- also in this subthread).
> But the specific form of this announcement is industry catch-up.
FWIW, this is just factually incorrect. Tesla has been shipping induction motors since the original Model S. They quite clearly led the EV industry in this particular technology. It wasn't until the Model 3 launched that they shipped their first permanent magnet drive train.
His management style may not be agreeable to people and he gets criticized for that a lot obviously. But the technical vision that he drives at Tesla, SpaceX, and his other companies are undeniable what makes these companies so valuable.
And it's exactly where his competitor's performance is less than stellar. Particularly at the companies you mention.
Tesla still CANNOT get their auto wipers to work correctly. This has been a feature on a Mazda 3 I had in 2007 and it worked flawlessly.
There are also 3 “non-auto” settings that work just like any other car.
I was interested in buying model Y. Rented a 2022. Wipers came on at dawn with 0 rain/snow. The next day wipers were not coming on during a snow storm.
Quick search showed that this is a common complaint among owners.
"Normal" car has wiper settings in the stalk. I don't want to crash trying to change wiper settings in the rain.
Same with SpaceX bringing an end to reliance on Russia. Without him, space industry would still be dangerously reliant on Putin.
Does anyone have a timestamp to where it's said in the video?