Methodology
Given the interdisciplinary nature of the project, and the fact that ambitious parallel development lines will be undertaken (3 advanced magnets lines and 3 final applications), the proposed methodology is based on a constant feedback work flow between disciplines in order to tailor and optimize BEETHOVEN magnet properties, maximize device performance, ensure sustainability of our solutions, transfer acquired skills and design the go-to-market strategy for each exploitable result (from the magnets themselves to the applications). It will consist of the following 4 steps, complemented by 3 transversal activities (Figure 1), and that contribute to the Objectives.
Step 1
Definition of requirements:
In a first step, engineers will model a first design of the generator (GS), E-motor (UU) and flywheel (WUP) prototypes. This will allow defining more accurately the requirements for BEETHOVEN magnets in terms of ranges of flux density, coercivity, energy product, size and the number of magnets needed to reach the targeted nominal outputs for each machine.
Step 2
Design and development of advanced materials:
Advanced materials in powder form will be developed according to 3 parallel development lines, namely HEA, W-type ferrite and nanowire composite magnetic materials. These developments rely on crucial technologies and innovations that BEETHOVEN partners are world experts on. The main aim of this step is to supply high performing powders to produce the BEETHOVEN magnets (Step 3) to be incorporated in the Green applications (Step 4). The materials will be developed considering the criteria defined in Step 1 and sustainability assessment and socio-economic studies.
Step 3
Upscaling and fabrication of advanced magnets:
The powder supplied by Step 2 will be employed to fabricate dense magnets, in the next logical step for the 3 magnet development lines. The main goals of this step are: 1. Upscale the production of magnetic materials from grams to kg/week in all three lines, 2. to fabricate sintered magnets with (BH)max > 55 kJ/m3 and bonded magnets with (BH)max > 23 kJ/m3, 3. Supply to Step 4 the kilograms of magnets needed in each final application. The LCA/s-TEA will inform the decisions on selected methods for upscaling and magnet production.
Step 4
Development of final applications prototypes with BEETHOVEN magnets:
With the support of the Life, technical and socio-economic cycle assessments (LCA/s-TEA) to inform decision-making, the magnets supplied in Step 3 will be integrated into the 3 prototypes to be developed in Step 4 of the project. Handling, integrating and magnetizing the magnets inside the prototypes is not a trivial task, and magnet producers (KOL, AMEN) will assist the engineers in this task.