In the heart of Hungary, the city of Szombathely is witnessing a revolution in electric vehicle (EV) motor recycling. Schaeffler, a global automotive and industrial supplier, has developed a groundbreaking process that extracts rare earth magnets from defective motor rotors and reuses them in new motors. This innovative approach, known as Pioneering Sustainability is not just a step forward for the company but for the entire automotive industry.
The project, which involved a team of seven specialists in Szombathely and two in Germany, focuses on factory scrap rather than end-of-life vehicles. This distinction is crucial as it addresses a different aspect of the recycling challenge. The neodymium-iron-boron (NdFeB) magnets, which are among the most expensive components in EV motors, are extracted using a specialized press, cleaned, and vacuum-packed for reuse. This method ensures that the magnets remain intact, unlike traditional chemical or metallurgical recycling processes that destroy the magnets to recover the rare elements.
Schaeffler’s Pioneering Sustainability Project
The Pioneering Sustainability project is a testament to Schaeffler’s commitment to sustainability and innovation. Tibor Szigeti, the managing director of Schaeffler in Hungary, emphasized the dual benefits of the project: “With this project, we not only protect our environment, but also serve the interests of our customers.” This initiative aligns with the broader goals of the Unione Europea‘s CIRCUIT4EU initiative, which aims to enhance the recycling of critical minerals.
The process begins with defective rotors from the production line. Engineers use a dedicated pressing technology to extract the magnets from the laminated core. These magnets are then thoroughly cleaned and packaged under vacuum, ready for their next use. Before being reinstalled, each magnet undergoes rigorous testing to ensure it meets the necessary standards. The magnets are then mounted using the same transfer molding method used for new components, where they are inserted into slots in the rotor’s laminated core and secured with injected resin.
The Advantages of Intact Magnet Recycling
One of the most significant advantages of Schaeffler’s method is that it keeps the magnets intact. This approach contrasts sharply with traditional recycling methods, such as those developed in the European project HARMONY which involve destroying the magnets to recover the rare elements. By preserving the magnets, Schaeffler’s process retains the value of the initial manufacturing work, reducing waste and lowering costs.
Schaeffler highlights that this process requires minimal investment and significantly reduces scrap and transport-related CO₂ emissions. However, the company has not yet published specific data on recovery rates, scrap rates, or actual costs. The potential to extend this method to end-of-life vehicle motors remains a challenge, as these magnets may be worn, contaminated, or assembled using different techniques.
The Broader Context of EV Motor Recycling
The automotive industry is under increasing pressure to address the sustainability of EV motor production. The reliance on rare earth magnets, which are primarily sourced outside of Europe, poses significant challenges for supply chain security and environmental impact. Schaeffler’s Pioneering Sustainability project is a step towards addressing these challenges by creating a closed-loop system for magnet recycling within the production process.
While other manufacturers are exploring motors without rare earth magnets, Schaeffler’s approach offers a practical solution for the immediate future. By reusing intact magnets, the company is not only reducing its environmental footprint but also ensuring a more stable supply of critical materials for its customers. This innovative method sets a new standard for sustainability in the automotive industry, paving the way for future advancements in EV motor recycling.
