In the transition towards sustainable mobility, Circular Design principles are
crucial. Electric Motors are subject to continuous innovation to improve
efficiency, performance density and reduce externalities associated with their
production. Therefore, the choice of technological solutions during design phase
must guarantee optimal performance and minimal environmental impact throughout
the entire product life cycle: production, use, and end-of-life. In the
automotive sector, the use phase is particularly critical since the efficiency
of the traction system is directly related to total energy consumption during
the life cycle and, consequently, to its environmental impact. This research
introduces a simulation-based approach to evaluate the use phase of an Axial
Flux Electric Motor equipped with Permanent Magnets (AFPM). While providing high
performance for electric traction motors, these magnets are composed of Rare
Earth Elements (REEs), e.g. Neodymium, classified as Critical Raw Materials
(CRMs) due to limited availability and environmental concerns associated with
extraction and processing. However, the high torque and power density of this
motor technology can potentially reduce the use of CRMs compared to other design
solutions. The primary objective of this study is to show a preliminary scalable
model that allows designers to evaluate motor performance under different design
choices and use scenarios, defined through standard or custom driving cycles,
providing immediate feedback in terms of environmental impact. The latter is
evaluated by analyzing the powertrain’s energy consumption and efficiency using
a road vehicle model, compiling the use phase inventory quickly, and simplifying
access to information. This preliminary model thus serves as a decision-support
system to balance performance optimization and environmental sustainability
during the design phase. This work is part of a framework aimed at improving
circularity of industrial products, particularly in the automotive industry.
Incorporating environmental factors in design phases encourages innovative
solutions that enhance efficiency and decrease reliance on limited
resources.