January 02, 2024 – With the rise in electric vehicle sales, the demand for electric motors is increasing, leading to challenges at the end of their lifecycle. Traditionally, these motors are shredded for recycling, resulting in the loss of valuable components and raw materials. To address this issue, the REASSERT project at the Fraunhofer Institute for Manufacturing Engineering and Automation IPA is exploring innovative strategies for remanufacturing and reusing electric motors within a circular economy framework.

The REASSERT initiative aims to develop a prototype electric motor designed specifically for the circular economy, promoting sustainability and resource efficiency. Current recycling methods often fail to recover crucial materials such as copper and rare earth elements like neodymium, which are vital for motor production. Extending the lifecycle of these motors is critical, as the raw materials involved have a significant carbon footprint compared to traditional combustion engines. Julian Große Erdmann, a scientist at Fraunhofer, emphasizes the potential of value retention strategies to reduce emissions and promote sustainability.

Collaborating with industry partners, including Schaeffler and the Karlsruhe Institute of Technology, the project focuses on various methods of reuse, repair, remanufacturing, and material recycling. By establishing a closed-loop system, the project seeks to minimize raw material extraction and reliance on imports. The proposed process includes inspecting, disassembling, and reconditioning motors, with the goal of reusing entire components where possible.

Additionally, an AI decision-making tool will aid in selecting optimal value retention strategies based on digital twin data of the motors. The knowledge gained from REASSERT will inform the design of future electric motors, ensuring they can be easily disassembled and integrated into sustainable practices.

Find the original press release here.