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Corresponding author: Joachim Osheyor Gidiagba.
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Modern electric motors: A review of sustainable design and maintenance principles:
scrutinizing the latest trends focusing on motor efficiency, sustainability,
recyclability, and reduced maintenance
Abimbola Oluwatoyin Adegbite 1, Chinedu Nnamdi Nwasike 2, Nwabueze Kelvin Nwaobia 3, Joachim Osheyor
Gidiagba 4, *, Oseluole Tobi Enabor 5, Samuel Onimisi Dawodu 6, Adedayo Adefemi 7 and Chinedu Alex
Ezeigweneme 8
1 IHS Towers Nigeria Plc, Nigeria.
2 High Auto Maintenance Services, Port-Harcourt, Nigeria.
3 Feratto Industries Limited, Aba, Nigeria.
4 Department of Mechanical and Industrial Engineering, University of Johannesburg, South Africa.
5 Department of Electrical and Electronics Engineering, University of Johannesburg, South Africa.
6 Nigeria Deposit Insurance Corporation, Nigeria.
7 Chevron Nigeria Limited, Nigeria.
8 MTN Nigeria.
World Journal of Advanced Research and Reviews, 2023, 20(03), 1198–1211
Publication history: Received on 05 November 2023; revised on 14 December 2023; accepted on 16 December 2023
Article DOI: https://doi.org/10.30574/wjarr.2023.20.3.2560
Abstract
This study presents a comprehensive review of the current state and advancements in sustainable electric motor design,
focusing on aspects of efficiency, sustainability, recyclability, and maintenance. The research employs a systematic
literature review methodology, analyzing peer-reviewed articles, conference papers, and academic theses from the past
decade. The aim is to synthesize existing knowledge and identify trends, challenges, and opportunities in the field of
electric motor technology, particularly in the context of environmental sustainability and technological innovation. Key
findings highlight a significant shift from conventional motor designs to more energy-efficient and environmentally
friendly models. The study reveals advancements in the use of sustainable materials, innovative manufacturing
processes, and the integration of cutting-edge technologies to enhance motor efficiency. The importance of recyclability
and effective maintenance strategies in extending the lifecycle of electric motors is also emphasized, alongside the
critical role of international standards and regulations in shaping industry practices. The future landscape of electric
motor technology is marked by both challenges and opportunities, with technological advancements paving the way for
further improvements in efficiency and sustainability. However, the need for more sustainable materials, improved
recycling processes, and adaptation to evolving regulatory landscapes presents ongoing challenges. The study concludes
with recommendations for industry leaders and policymakers, emphasizing the need for continuous investment in
research and development, embracing circular economy principles, and fostering collaboration between various
stakeholders. Future research directions are suggested, focusing on exploring new materials and technologies,
developing standardized methods for environmental impact assessment, and promoting effective recycling and
maintenance strategies. This comprehensive review serves as a valuable resource for stakeholders in the electric motor
industry, providing insights and guidance for future developments in sustainable electric motor technologies.
Keywords: Electric Motor Design; Energy Efficiency; Recyclability; Maintenance; Motor Technology
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1. Introduction
1.1. The Emergence of Modern Electric Motors in Sustainable Engineering
The evolution of modern electric motors marks a significant stride in sustainable engineering, driven by the urgent need
to address energy and environmental challenges (Bilgin and Emadi, 2014). This transformation is underscored by the
shift towards high-efficiency induction motors, which are pivotal in minimizing energy loss and mitigating
environmental impacts (Gheorghe et al., 2016). The development of these motors is regulated by efficiency standards,
posing a continuous challenge for manufacturers to innovate and improve their designs.
Electric vehicles (EVs) have emerged as a primary focus in the quest for sustainable transportation, with electric motors
playing a crucial role. The rapid advancement of the global automobile industry has brought energy and environmental
issues to the forefront, making electric vehicles a key direction for new energy development (Wu et al., 2021). This shift
is supported by the maturation of energy storage technologies, high efficiency of driving motors, and advanced control
modes, positioning electric vehicles as the mainstay in the new energy vehicle sector.
The design of electric motors for EVs is a complex task, requiring a balance between high efficiency, high power density,
wide speed regulation, and high overload capacity. The sine wave permanent magnet brushless motor, for instance,
represents a significant innovation in this field. Its design involves intricate considerations like the selection of stator
slots, winding design, and electromagnetic load parameters, all aimed at optimizing performance (Wu et al., 2021).
These motors are designed to meet the stringent performance indices of pure electric vehicles, reflecting the industry's
commitment to sustainable mobility.
The transition to sustainable electric motors is not just about technological innovation but also involves a paradigm
shift in how we approach energy consumption and environmental impact. The normative framework for developing
energy-efficient induction motors includes analyzing energy consumption during fabrication and operation, opening
avenues for upgrading existing designs to more economical and environmentally friendly units (Gheorghe et al., 2016).
This approach is crucial in reducing the carbon footprint and overall costs associated with electric motors, making them
a cornerstone in sustainable engineering.
The emergence of modern electric motors in sustainable engineering is a response to global energy and environmental
challenges. The focus on high-efficiency induction motors and innovations in electric vehicle motor design exemplifies
the industry's commitment to sustainable development. These advancements are not only technological feats but also
represent a broader shift towards a more sustainable and environmentally conscious approach to engineering.
1.2. Defining the Scope: Efficiency, Sustainability, Recyclability, and Maintenance
Modern electric motors are at the forefront of sustainable engineering, with their design and operation increasingly
focused on efficiency, sustainability, recyclability, and maintenance. These aspects are crucial in addressing the
environmental and energy challenges of our times.
Efficiency: The efficiency of electric motors is a critical factor in their overall sustainability. High-efficiency motors,
typically operating with efficiencies between 80 and 90%, are increasingly sought after in various applications, from
industrial machinery to electric vehicles (Kaya, Kılıç, & Öztürk, 2023). These motors are designed to maximize energy
output while minimizing losses, often achieved through improved winding techniques, better materials, and more
efficient rotor designs. The correct sizing of electric motors is essential, as motors reach maximum efficiency at 75–80%
load and running them under low load can lead to overheating and reduced lifespan.
Sustainability: The sustainability of electric motors encompasses their entire lifecycle, from production to end-of-life
management. Mayr et al. (2018) highlight the importance of considering the market, product, and process perspectives
in assessing the sustainability of electric motors. This includes state-regulated efficiency classes, the range of motor
types and their sustainability characteristics, and the energy and resource efficiency of manufacturing processes. The
holistic view of these aspects ensures that electric motors contribute positively to environmental goals.
Recyclability: The end-of-life management of electric motors is gaining attention, with a focus on recycling and the
circular economy. Tiwari et al. (2021) emphasize the importance of developing strategies for the high-value materials
in electric motors, noting that recycling is a key area of research. However, reuse, which ranks higher in the waste
hierarchy, is less explored due to challenges in assessing the condition and availability of returned products. This
highlights the need for more research and development in the recyclability and reuse of electric motor components.
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Maintenance: Maintenance plays a vital role in the sustainability of electric motors. Efficient maintenance strategies
can significantly extend the life of a motor, thereby reducing its environmental impact. Konovalov et al. (2023) discuss
the advancements in cooling systems for electric motors, which are crucial for maintaining operational efficiency and
reliability. These developments include air and liquid cooling systems, which are essential for managing the
temperature distribution in motors and thus enhancing their performance and longevity.
The scope of modern electric motors in sustainable engineering is broad, encompassing efficiency, sustainability,
recyclability, and maintenance. Each of these aspects plays a crucial role in the design, operation, and end-of-life
management of electric motors, contributing to the overarching goals of sustainable development and environmental
conservation.
1.3. Historical Evolution of Electric Motors: From Conventional to Sustainable Models
The historical evolution of electric motors, from their conventional forms to modern sustainable models, is a narrative
of technological innovation and environmental consciousness. This journey reflects the changing priorities in
engineering and manufacturing, with a growing emphasis on efficiency, sustainability, and environmental impact.
The inception of electric motors dates back to the 19th century, with the pioneering work of inventors like Michael
Faraday and Nikola Tesla. These early motors were primarily direct current (DC) machines, used in small-scale
applications due to their simplicity and ease of control. However, their limited power output and efficiency made them
unsuitable for large-scale industrial use.
The introduction of alternating current (AC) motors, particularly induction motors, marked a significant advancement
in the field. These motors, developed by Tesla and others, offered higher power and efficiency, making them ideal for
industrial applications. The widespread adoption of AC motors was facilitated by the development of the power grid,
which provided a reliable source of alternating current.
The focus on efficiency gained momentum in the late 20th century, driven by the growing awareness of energy
conservation and environmental impact. This led to the development of high-efficiency motors, such as the six-phase
induction motor, which offers improved torque and reduced losses compared to traditional three-phase motors (Francis
et al., 2018). These motors are particularly beneficial in electric vehicle propulsion, contributing to sustainable
transportation.
The 21st century has seen a shift towards more sustainable and intelligent motor designs. This includes the integration
of advanced materials, innovative cooling systems, and smart control technologies. The use of rare-earth-free magnets,
for instance, addresses the environmental and geopolitical concerns associated with rare-earth elements. Additionally,
the incorporation of Internet of Things (IoT) and artificial intelligence (AI) technologies in motor control systems has
led to more efficient and adaptive performance.
The role of electric motors in the evolution of electric vehicles (EVs) is pivotal. As the automotive industry moves
towards sustainable transportation, electric motors have become the cornerstone of this transition. The development
of efficient, high-torque motors for EVs is a key area of research, with significant advancements in motor design and
control strategies (Bohnsack et al., 2013).
The historical evolution of electric motors from conventional to sustainable models is a testament to the progress in
electrical engineering and technology. This evolution reflects the changing priorities of society, with a growing emphasis
on efficiency, sustainability, and environmental responsibility.
1.4. Aim and Objectives of the Review
The primary aim of this study is to systematically review and analyze the current state and advancements in sustainable
electric motor design. This includes evaluating the efficiency, sustainability, recyclability, and maintenance practices
associated with modern electric motors, with a focus on their application in various industries, particularly in the
context of environmental sustainability and technological innovation.
The objectives are to;
To explore current trends in motor efficiency including the design and operational factors that contribute to enhanced
performance and energy savings.
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To explore the evolution of electric motor technology and the impact of sustainable electric motor technologies.
To determine the challenges in current electric motor designs and potential solutions.
1.5. Significance of the Study
The significance of this study on sustainable electric motor design is multifaceted, encompassing environmental,
technological, industrial, and policy-related impacts. It provides a comprehensive analysis of the current state and
advancements in electric motor technology, with a focus on sustainability, efficiency, recyclability, and maintenance.
This research is crucial in the context of global environmental challenges, as electric motors play a pivotal role in various
industries. By highlighting sustainable design principles and the latest technological innovations, the study contributes
to the reduction of environmental impact and promotes energy conservation. It serves as a valuable resource for
manufacturers and industry stakeholders, offering insights that inform better design, production, and maintenance
practices aligned with sustainability goals. Additionally, the study's findings offer a framework for policymakers,
guiding the development of regulations and standards that support the use of sustainable electric motors. The
identification of gaps and future research opportunities within the study is vital for academics and researchers, directing
efforts towards areas with the most significant potential impact. Furthermore, by addressing recyclability and
maintenance strategies, the study aligns with the principles of the circular economy, emphasizing resource efficiency
and lifecycle management in industrial processes. Overall, the study's significance lies in its contribution to
environmental sustainability, technological advancement, and the provision of practical guidance for industry and
policy, making it an essential resource for stakeholders in the field of electric motor technology.
2. Methodology
2.1. Research Design for Analyzing Sustainable Electric Motor Design
The research design for analyzing sustainable electric motor design is structured to systematically review and
synthesize existing literature. This involves a comprehensive search strategy to identify relevant studies, followed by a
critical appraisal of the identified literature. The focus is on studies that address various aspects of sustainable electric
motor design, including energy efficiency, use of sustainable materials, manufacturing processes, and lifecycle analysis.
2.2. Criteria for Selecting Relevant Studies on Electric Motor Sustainability
The selection criteria for relevant studies are based on several key parameters:
Relevance to Sustainable Design: Studies must focus on sustainable design aspects of electric motors, including
energy efficiency, environmental impact, and use of renewable resources.
Publication Date: Preference is given to studies published in from 2008 to 2023 to ensure the review
incorporates the latest advancements and trends.
Peer-Reviewed Sources: Only peer-reviewed journal articles, conference papers, and academic theses are
considered to ensure the credibility and reliability of the information.
Language: Studies published in English are primarily considered due to language proficiency constraints.
2.3. Data Collection and Analysis
2.3.1. Identifying Key Studies in Sustainable Electric Motor Design
Identifying Key Studies in Sustainable Electric Motor Design
The identification of key studies involves:
Database Search: Utilizing academic databases like IEEE Xplore, ScienceDirect, and Google Scholar to find
relevant literature.
Keyword Search: Employing specific keywords such as "sustainable electric motor design," "energy-efficient
motors," "eco-friendly motor manufacturing," etc.
Reference Tracking: Reviewing references of identified articles to find additional relevant studies.
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2.3.2. Analytical Methods for Evaluating Motor Efficiency and Sustainability
The analytical methods include:
Content Analysis: Thoroughly examining the content of selected studies to extract data on motor design,
efficiency, sustainability practices, and technological innovations.
Comparative Analysis: Comparing findings across different studies to identify common themes, trends, and
gaps in the research.
Quality Assessment: Evaluating the methodological quality of each study to determine the strength of the
evidence presented.
3. Literature Review
3.1. Core Principles of Sustainable Electric Motor Design
The design of sustainable electric motors is guided by core principles that focus on efficiency, environmental impact,
and long-term viability. These principles are essential in addressing the growing demand for eco-friendly and energy-
efficient technologies in various sectors, including transportation and industrial applications.
The design of a 300W axial flux motor for an electric bike by Tung et al. (2021) exemplifies the principle of maximizing
power density and efficiency. Their design utilizes axial-flux machine topology and Halbach-array to increase power
density, while simplifying the manufacturing process and reducing core weight. This approach not only enhances the
motor's performance but also contributes to its sustainability by reducing material usage and energy consumption.
The study on switched reluctance motor design for electric vehicles by Bukhari et al. (2019) highlights the importance
of adaptability to harsh environments and fault tolerance in sustainable motor design. Their research proposes a 20
kW, three-phase switched reluctance motor, optimized for high torque density and efficiency in electric vehicle
applications. The motor's design addresses the challenges of high-temperature environments and demagnetization of
permanent magnets, showcasing the adaptability and reliability essential in sustainable motor design.
The critical aspects of electric motor drive controllers and mitigation of torque ripple, as discussed by Mohanraj et al.
(2022), are fundamental in sustainable motor design. Their literature survey compares various advanced control
techniques for conventionally used electric vehicle motors, focusing on minimizing torque ripple and enhancing
reliability. This principle is crucial in ensuring the long-term performance and sustainability of electric motors,
particularly in electric vehicles.
The design of a coreless multi-phase electric motor using magnetic resonant coupling by Besong & Fujimoto (2022)
represents the principle of lightweight and innovative design. Their novel coreless motor, made of reinforced plastic
fibers and 3-D printed components, drastically reduces weight while maintaining efficiency. This design approach is
significant in sustainable motor design, as it reduces material usage and energy consumption, contributing to the overall
sustainability of the motor.
The core principles of sustainable electric motor design encompass maximizing power density and efficiency,
adaptability to harsh environments and fault tolerance, mitigation of torque ripple and improved reliability, and
lightweight and innovative design. These principles are integral in developing electric motors that are not only efficient
and high-performing but also environmentally friendly and sustainable.
3.2. Architectural Innovations in Modern Electric Motors
Architectural innovations in modern electric motors have been pivotal in enhancing their efficiency, sustainability, and
adaptability to various applications. These innovations are characterized by advancements in design, materials, and
technology, contributing significantly to the evolution of electric motors.
The study by de Souza et al. (2022) provides an insightful analysis of the performance evolution in squirrel-cage rotor
three-phase induction electric motors (SCIMs) from 1945 to 2020. This research highlights the significant performance
gains achieved through innovations in insulating materials, cooling housing, bearings, and overall design. The evolution
from cotton and silk to modern varnishes for insulating electrical conductors, along with improvements in mechanica l
components, has led to a substantial increase in efficiency and a reduction in the weight/power ratio of these motors.
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This historical perspective underscores the continuous architectural innovation in electric motors, contributing to their
sustainability and efficiency.
The comparative study by Bhatt, Mehar, and Sahajwani (2019) on electric motors used in electric vehicles provides a
comprehensive overview of the various classes of motors and their evolution over time. This study emphasizes the
importance of efficiency, power density, reliability, and size in the selection of electric motors for electric vehicles. The
paper discusses how different types of electric motors have been adapted and optimized for specific power
requirements, showcasing the architectural innovations that have been made to meet the growing demands of the
electric vehicle industry.
Padovani, Ketelsen, and Schmidt (2020) explore the use of hybrid technologies in downsizing electric motors for energy-
efficient self-contained electro-hydraulic systems. Their research presents a novel approach to reducing the size of
electric motors while maintaining high power output, particularly in high-power applications. This study demonstrates
the feasibility of hybridizing self-sufficient systems, offering a promising solution for enhancing the efficiency and
sustainability of electric motors in demanding environments.
Architectural innovations in modern electric motors are characterized by advancements in materials, design, and
technology. These innovations have led to significant improvements in efficiency, sustainability, and adaptability,
making electric motors more suitable for a wide range of applications, including electric vehicles and electro-hydraulic
systems.
3.3. Approaches to Enhancing Motor Efficiency and Sustainability
In the realm of electric motors, enhancing efficiency and sustainability is a multifaceted challenge that involves various
approaches, ranging from market developments to innovative manufacturing processes and eco-driving strategies.
These approaches are crucial in minimizing energy loss and environmental impact, thereby contributing to the broader
goals of sustainable development.
Mayr et al. (2018) provide a comprehensive analysis of the sustainability aspects of electric motors, considering market
developments, product types, and innovative manufacturing processes. Their study emphasizes the significance of the
electric motor industry and the importance of state-regulated efficiency classes. By analyzing different product types
and their sustainability characteristics, along with manufacturing processes in terms of energy and resource efficiency,
the paper offers a holistic view on the sustainability aspects of electric motors. This approach underlines the importance
of integrating market, product, and process perspectives to enhance the sustainability of electric motors.
Gheorghe et al. (2016) focus on the development of high-efficiency induction electric motors to minimize energy loss
and environmental impact. The paper outlines the normative framework for developing energy-efficient induction
motors and analyzes energy consumption during their fabrication and operation. By presenting case studies on
improving induction motor technical features based on numerical analysis, the research evaluates upgraded versions
of induction motors against their basic units. This approach highlights the potential of upgrading existing designs to
more economical and environmentally friendly units.
Koch et al. (2021) propose an online nonlinear algorithm for eco-driving, which optimizes the speed profile and
powertrain operation for electric vehicles with multiple motors and gears. This paper addresses the non-convex power
demand of electric motors and compares different powertrain topologies in various scenarios. The research validates
the proposed algorithm through Dynamic Programming, demonstrating how optimal speed profiles and powertrain
configurations can lead to reduced energy consumption. This approach is significant in enhancing motor efficiency and
sustainability in electric vehicles.
Auer and Meincke (2018) conduct a comparative life cycle assessment of electric motors from different efficiency
classes. Their study evaluates the trade-offs between the life cycle stages, particularly between manufacturing and use
stages. By analyzing the environmental impacts of motors with asynchronous technology, the research indicates the
dominance of the use stage in the motors' life cycles and the environmental benefits of increased efficiency. This
approach provides insights into the environmental break-even points and the balance between energy-related impacts
and toxicity/resource depletion-related impacts.
Approaches to enhancing motor efficiency and sustainability involve a comprehensive understanding of market trends,
product development, manufacturing processes, and operational strategies. These approaches, ranging from holistic
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sustainability analysis to eco-driving algorithms and life cycle assessments, are essential in developing electric motors
that are not only efficient but also environmentally sustainable.
3.4. Milestones in the Development of Sustainable Electric Motors
The development of sustainable electric motors has been marked by significant milestones, reflecting the evolution o f
technology, materials, and design principles. These milestones have played a crucial role in shaping the current
landscape of electric motor technology, particularly in the context of ecological automotive transports, lightweight
motor design, and solar-powered electric vehicles.
The research by Neamțu and Țîțu (2021) delves into the durable and sustainable development of ecological automotive
transports, focusing on electric motor vehicles. Their study presents a technical and managerial perspective, including
a SWOT analysis of electric motor vehicles and their quality assessment indicators. The article highlights the challenges
and opportunities in the electric motor vehicle sector, emphasizing the need for sustainable development in this field.
This milestone reflects the growing importance of electric motors in the automotive industry and the shift towards more
sustainable and efficient transportation solutions.
The work by Ruff et al. (2014) on the development of lightweight sustainable electric motors using nanoscale materials
represents a significant milestone in electric motor technology. Their research describes the design of a lightweight
electric motor, emphasizing the use of nanoscale materials to enhance sustainability and performance. This milestone
is indicative of the evolving focus on material innovation and lightweight design in electric motor development, catering
to the needs of various applications, including electric vehicles.
The study by Sain et al. (2020) provides an extensive review of solar-powered energy-efficient smart electric vehicles
based on permanent magnet synchronous motor (PMSM) drive. This research addresses the integration of solar energy
in electric vehicles and the advancements in aerodynamic design and IoT tools for smart electric vehicles. This milestone
highlights the convergence of renewable energy and electric motor technology, showcasing the potential of solar power
in enhancing the sustainability of electric vehicles.
Although not directly related to electric motor development, the analysis of torque capability and limits of operation of
AC traction motors on sustainable high-speed electric trains by Sain et al. (2020) offers insights into the sustainability
aspects of electric railway systems. This research emphasizes the importance of energy conversion efficiency in electric
traction motors and their impact on the environmental performance of electric trains. This milestone underscores the
relevance of electric motors in sustainable transportation systems beyond automotive applications.
Going forward, the milestones in the development of sustainable electric motors reflect the ongoing efforts to enhance
efficiency, reduce environmental impact, and integrate innovative materials and renewable energy sources. These
developments are pivotal in shaping the future of electric motor technology and its applications in various sectors.
3.5. Cutting-Edge Technologies in Electric Motor Design
The design of electric motors has seen remarkable advancements with the integration of cutting-edge technologies.
These innovations are pivotal in enhancing the efficiency, performance, and sustainability of electric motors,
particularly in the context of large consumer products, aviation, and electric vehicle applications.
Nemoianu et al. (2019) explore the challenges and trends in electric motors of large consumer products, particularly
focusing on power efficiency improvement through modern cutting technologies. Their study reviews the main sources
of overall efficiency degradation, such as energy steel losses, and presents specific methods to address these issues. The
research emphasizes the global impact of small energy consumption reductions in large-scale industrial manufacturing
of consumer goods. This advancement in power efficiency is a crucial step in the sustainable development of electric
motors, especially considering the generalization of the IE4 efficiency standard.
Deisenroth and Ohadi (2019) discuss the revolutionary impact of enhanced cooling, novel designs, and packaging of
semiconductors on electric motors, particularly in aviation. Their paper focuses on the thermal management of high-
power density electric motors, which is essential for the electrification of aviation. The study highlights the role of
electromagnetic and thermo-mechanical co-design, enabled by innovative design topologies, materials, and
manufacturing techniques. This approach is significant in realizing the performance and cost metrics of next-generation
electric motors.
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Kuehl (2023) presents a flexible, robot-based cutting process of hairpin windings developed for electric motors. This
technology is particularly advantageous in automating the production process of electric motors in high-wage countries.
The research emphasizes the importance of a clean and burr-free cut surface for the subsequent joining of the wire into
the stator, ensuring a trouble-free process flow and appropriate current flow. The hairpin technology and its associated
process chain represent a significant advancement in the manufacturing of electric motors.
Goli et al. (2021) provide a comprehensive review of several topologies of traction motors employed in electric vehicle
traction applications. The paper emphasizes trends in volumetric power density and gravimetric power density of
traction motors, which directly affect the weight, packaging, and efficiency of electric vehicles. The study classifies motor
topologies based on permanent magnet use, the location of the magnets inside the motor, and design trends in rotor
and stator. This analysis offers a useful reference for understanding product evolution and forecasting future trends in
electric motor technologies.
The integration of cutting-edge technologies in electric motor design is transforming the efficiency, performance, and
sustainability of these motors. Innovations in power efficiency, thermal management, manufacturing processes, and
motor topologies are driving the advancement of electric motors in various applications, from consumer products to
aviation and electric vehicles.
3.6. Trends in Electric Motor Sustainability and Maintenance
The sustainability and maintenance of electric motors are critical aspects in their lifecycle, impacting both their
performance and environmental footprint. Del Pero et al. (2021) conducted a comprehensive environmental
sustainability analysis of Formula-E electric motors. Their study developed a tailored methodological approach to
assess the environmental impacts of the whole life cycle of a Formula-E electric motor. The research emphasized the
importance of eco-design and technology transfer from racing high-performance cars to commercial vehicles. This
analysis is significant in understanding the environmental implications of electric motors in high-performance
applications and their potential for sustainable urbanization.
Bentivogli et al. (2022) presented a novel approach to predictive maintenance in industrial electric motors. Their paper
introduced a deploy-and-forget sensor node for predictive maintenance, targeting three-phase asynchronous motors.
This technology supports data collection from multiple sensors and features ultra-low-power design, achieving self-
sustainability. The sensor node's ability to anticipate deterioration and incoming breakages on operating machines is
crucial in reducing maintenance costs and enhancing the reliability of electric motors.
Parpala and Jacob (2017) discussed the application of IoT technologies for predictive maintenance of industrial
equipment. The paper highlighted the evolution of technologies enabling monitoring, tests, and diagnostics of in-service
electric motors, surpassing traditional RMS current and voltage measurements. The ability to use a working, online
motor as a transparent sensor producing shaft torque signatures at the motor control cabinet enables advanced
diagnoses of voltage supply, motor, and load system conditions. This advancement is pivotal in predictive maintenance
strategies, ensuring efficient and timely maintenance interventions.
Polonelli et al. (2022) explored the development of a self-sustainable IoT wireless sensor node for predictive
maintenance on electric motors. The sensor is designed for AC mono and three-phase asynchronous motors and
generators, measuring vibrations, environmental noise, temperature, and the external magnetic field. The prototype's
capability to detect anomalies using vibration spectral analysis is a significant step forward in predictive maintenance,
offering just-in-time services at reduced operational costs.
The trends in electric motor sustainability and maintenance are characterized by a focus on environmental
sustainability, predictive maintenance technologies, and the application of modern monitoring techniques. These
advancements are essential in enhancing the performance, reliability, and environmental compatibility of electric
motors.
3.6.1. Innovations in Sustainable Materials and Manufacturing Processes
The evolution of electric motors has been significantly influenced by innovations in sustainable materials and
manufacturing processes. This examines the latest advancements in this area, focusing on lightweight design
approaches, sustainability aspects of electric motors, and the use of rare earth elements and composite materials.
Peter et al. (2013) explored new conceptual lightweight design approaches for the integrated manufacturing processes
of electric motors. Their study focused on the influence of alternative materials on the process chain of electric motor
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manufacturing, particularly for traction motors in electric vehicles. The research highlighted the challenges and
opportunities in variant flexible and scalable production processes, emphasizing the use of lightweight materials to
lower the environmental impact. This approach is crucial in meeting the increasing demand for electric traction systems
and enhancing the economical relevance of production processes (Peter et al., 2013).
Mayr et al. (2018) provided a comprehensive overview of the sustainability aspects of electric motors from market,
product, and process perspectives. The study analyzed the electric motor market, emphasizing the significance of state-
regulated efficiency classes. It also examined different electric motor types and their sustainability characteristics, along
with an analysis of manufacturing processes in terms of energy and resource efficiency. This holistic view on
sustainability aspects offers valuable insights into optimizing electric motor production for environmental and
economic benefits (Mayr et al., 2018).
Bailey et al. (2017) addressed the sustainability of permanent rare earth magnet motors in the hybrid/electric vehicle
(H/EV) industry. The study reviewed the technical, social, environmental, and economic aspects of rare earth elements
(REEs) used in these motors. It highlighted the environmental challenges associated with the production and processing
of REEs, as well as the price volatility that affects their economic sustainability. This research is significant in
understanding the comprehensive impact of rare earth elements in the electric vehicle industry and exploring
alternatives for more sustainable motor designs (Bailey et al., 2017).
Choi et al. (2023) reviewed the latest applications of composite materials in modern vehicles and evaluated the state of
the art of composite manufacturing and recycling processes for green mobility. The study emphasized the trade-offs
between performance and cost in the mass adoption of composites. It also discussed the integration of robotic
automation into composite manufacturing processes for eco-friendly, sustainable, and cost-effective production. This
research is pivotal in advancing the use of composites for lightweight and efficient electric motor designs (Choi et al.,
2023).
The innovations in sustainable materials and manufacturing processes for electric motors are characterized by a focus
on lightweight design, comprehensive sustainability analysis, the use of rare earth elements, and the application of
composite materials. These advancements are essential in enhancing the performance, reliability, and environmental
compatibility of electric motors.
3.6.2. Advances in Maintenance Strategies and Lifecycle Management
The maintenance strategies and lifecycle management of electric motors are critical aspects that determine their
efficiency, reliability, and overall performance. It explores recent advances in these areas, focusing on optimizing
repairs, circular economy research, cooling systems, and predictive maintenance using machine learning.
Mironenko & Khalyasmaa (2023) investigated the optimization of repairs and maintenance of electrically driven gas
pumping units. Their study analyzed the existing approach to the operation and maintenance of these units, utilizing
life cycle management systems to assess their current state. The research employed machine learning algorithms, such
as bagging and gradient boosting, to monitor diagnostic and operational parameters, thereby enhancing the accuracy
in assessing the current state of electrically driven gas pumping units. This approach is vital for reducing costs and
increasing the service life of these units (Mironenko & Khalyasmaa, 2023).
Tiwari et al. (2021) provided a holistic view of circular economy research for electric motors, emphasizing the role of
Industry 4.0 technologies. The paper highlighted the lack of a methodology for selecting the best end-of-life scenario for
industrial electric motors and identified recycling as a key focus area. The study also revealed that reuse, a better
strategy in terms of waste hierarchy, was the least researched area. This research is crucial for understanding the
current landscape and identifying challenges and recommendations for future research in the circular economy of
electric motors (Tiwari et al., 2021).
Konovalov et al. (2023) explored new trends in the development of cooling systems for electric motors. The study
summarized academic research and patents for cooling systems, focusing on temperature distribution and its influence
on the power-to-dimension ratio of electric motors. The research discussed air and liquid cooling systems, highlighting
their potential to increase the power-to-dimension ratio and reduce motor size. This study is significant in
understanding the advancements in cooling management, which is essential for the efficient operation and maintenance
of electric motors (Konovalov et al., 2023).
World Journal of Advanced Research and Reviews, 2023, 20(03), 1198–1211
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Chimundu & Ali (2022) examined the application of machine learning in predictive maintenance of electric motors. The
study focused on classification models that categorize critical factors affecting motor performance, such as the
surrounding environment, running temperature, motor speed, and load current. This research is important for
developing cost-effective maintenance strategies that ensure the viability and longevity of electric motors (Chimundu
& Ali, 2022).
Based on this finding, the advances in maintenance strategies and lifecycle management for electric motors are
characterized by a focus on optimizing repairs, circular economy, cooling management, and predictive maintenance
using machine learning. These advancements are essential in enhancing the performance, reliability, and environmental
compatibility of electric motors.
4. Discussion
4.1. Evaluating the Impact of Sustainable Electric Motor Technologies
The impact of sustainable electric motor technologies extends across technological, economic, and environmental
dimensions by delving into the implications of these technologies, focusing on their role in urban mobility, economic
and social considerations, and life cycle assessment.
Del Pero et al. (2021) conducted an environmental sustainability analysis of the Formula-E electric motor, focusing on
its life cycle impacts. The study developed a methodological approach to assess the environmental impacts throughout
the life cycle of a Formula-E electric motor, including the production, use, and end-of-life stages. This research is
significant in understanding the environmental footprint of high-performance electric motors and offers insights for
eco-design and technology transfer from racing to commercial vehicles (Del Pero et al., 2021).
Palaniswamy et al. (2022) provided a comprehensive overview of the social, economic, and environmental impacts of
electric vehicles (EVs) in India. The study highlighted the role of EVs in addressing global warming, fuel dependence,
and greenhouse gas emissions. It also discussed the government's support in promoting EV adoption and the challenges
related to battery manufacturing and charging infrastructure. This research is crucial for understanding the
multifaceted impacts of electric vehicles, including those powered by sustainable electric motors, in a rapidly developing
economy (Palaniswamy et al., 2022).
Tintelecan et al. (2019) explored the environmental impact of electric vehicles through Life Cycle Assessment (LCA).
The study focused on setting up indicators for a more accurate analysis of the environmental impact of battery electric
vehicles, including the electric motors. It emphasized the importance of considering the entire life cycle of EV
components, such as permanent magnets in electric motors, to assess their sustainability. This research is important for
evaluating the environmental implications of electric motor technologies in the context of sustainable transport
(Tintelecan et al., 2019).
Therefore, the impact of sustainable electric motor technologies is multifaceted, encompassing environmental
sustainability, social and economic considerations, and life cycle impacts. These studies provide valuable insights into
the broader implications of adopting sustainable electric motors in various sectors, particularly in urban mobility and
electric vehicles.
4.1.1. Challenges in Current Electric Motor Designs and Potential Solutions
The development of electric motor technologies faces numerous challenges, ranging from manufacturing complexities
to performance optimization. Wößner et al. (2021) explored the technical challenges in producing permanent magnet
rotors for electric traction motors, particularly those designed for high power densities. The study emphasized the
difficulties in managing initial unbalances and changes during operation, which are critical for the economically viable
and resource-saving production of highly efficient motors. The authors presented experimental investigations and FE-
simulations to prioritize challenges and approaches for unbalance reduction, offering optimization potentials for the
production of permanent magnet rotors (Wößner et al., 2021).
Husain et al. (2021) discussed the evolving trends and challenges in electric drive technology for future electric vehicles.
The article highlighted the need for improved performances, such as fuel efficiency, extended range, and fast-charging
options. It also identified emerging materials and technologies for power electronics and electric motors, addressing
the challenges and opportunities for innovative drive and motor designs to meet the technical targets for light-duty
electric vehicles by 2025 (Husain et al., 2021).
World Journal of Advanced Research and Reviews, 2023, 20(03), 1198–1211
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Zhang et al. (2022) reviewed the development and critical technologies of Integrated Motor Drives (IMDs), which have
gained extensive attention in electric vehicles, electric propulsion aircraft, and ship propulsion systems. The paper
discussed the research progress in motor structure, converter, volume optimization, heat dissipation design, and
electromagnetic interference mitigation. It also explored the applications of wide-bandgap semiconductors and the
integration of LCL filters, highlighting the future potential of IMDs in applications requiring high power density (Zhang
et al., 2022). These studies provide insights into the complexities of manufacturing and optimizing electric motors,
offering potential pathways to overcome these challenges in the pursuit of sustainable and efficient electric motor
technologies.
4.1.2. Trends in Sustainable Design and Maintenance Practices
The evolution of electric motor technology is marked by ongoing trends in sustainable design and maintenance
practices. Matsuoka & Kondo (2010) addressed the challenge of reducing power consumption in the testing of traction
induction motors. The study emphasized the need for energy-saving technologies in the testing phase, which is crucial
for both quality assurance and environmental sustainability. The research highlighted the importance of efficient testing
methods for traction motors, particularly in the context of their widespread application in electric vehicles and other
high-power applications (Matsuoka & Kondo, 2010).
Kotter et al. (2018) explored the challenges and opportunities in the electric vehicle segment of the automotive industry.
Their work included the development of a common virtual physical environment, X-in-the-loop, for comprehensive
testing of electric vehicle components. This approach is significant for the sustainable design and maintenance of
electric motors, as it allows for the integration of various test rigs and software simulators to evaluate electric vehicle
systems in real-time (Kotter et al., 2018).
The study of Schuberth et al. (2008) discussed the use of stainless steel in reducing weight and costs while improving
safety and sustainability in automotive systems. The research emphasized the role of stainless steel in the future of car
manufacturing, particularly in the context of electric motor vehicles. This approach to material selection and design is
crucial for the sustainable development of electric motors, as it addresses key aspects such as weight reduction, cost
efficiency, and environmental impact (Schuberth et al., 2008). These studies provide insights into the evolving landscape
of electric motor technology, highlighting the importance of innovation and sustainability in this field.
4.2. Implications for Industry Stakeholders in Electric Motor Development
The development of sustainable electric motors has significant implications for various industry stakeholders, including
manufacturers, policymakers, and consumers. The shift towards electric vehicles (EVs) necessitates a reevaluation of
motor design to meet performance indices specific to EVs. Wu et al. (2021) emphasize the importance of designing
motors that can efficiently meet the demands of pure electric vehicles. This involves studying the characteristics of
various driving motors and selecting appropriate control schemes. Such research is crucial for manufacturers as it
guides the development of more efficient and sustainable motors, directly impacting the performance and marketability
of EVs (Wu et al., 2021).
The transition to a low-carbon economy, particularly in the electric vehicle sector, presents both challenges and
opportunities for stakeholders. Majid and Dalimi (2021) discuss the Indonesian government's policy on the Battery-
Based Electric Motor Vehicle Program, highlighting the need for sustainable development in the sector. Their study
using the Analytical Hierarchy Process method identifies key areas such as governance improvement, infrastructure
and technology development, and data availability as critical for sustainable development. This analysis is vital for
policymakers and industry leaders in strategizing for sustainable growth in the electric vehicle battery industry (Majid
& Dalimi, 2021)
The integration of solar energy into electric vehicles represents a significant advancement towards environmental
sustainability. Sain et al. (2020) discussed the development of solar-powered energy-efficient smart electric vehicles,
particularly focusing on permanent magnet synchronous motor (PMSM) drive technologies. This research is crucial for
the industry as it explores the potential of solar energy in reducing greenhouse gas emissions and promoting
environmental sustainability. The study also addresses the impact of emerging Information and Communication
Technology (ICT) in this field, which is of great interest to technologists and researchers working on future
developments in electric vehicles (Sain et al., 2020). These areas highlight the ongoing evolution and challenges in the
field, underscoring the need for continued innovation and collaboration among manufacturers, policymakers, and
researchers.
World Journal of Advanced Research and Reviews, 2023, 20(03), 1198–1211
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5. Conclusions
The study has systematically reviewed the current state of sustainable electric motor design, highlighting significant
advancements and trends. Key findings include the evolution from conventional to more energy-efficient and
environmentally friendly motors, the increasing focus on using sustainable materials, and the integration of innovative
technologies to enhance motor efficiency. The importance of recyclability and maintenance in extending the lifecycle of
electric motors has also been emphasized. Furthermore, the study has identified the critical role of international
standards and regulations in guiding the development of sustainable electric motors.
Looking forward, the electric motor industry faces both challenges and opportunities. Technological advancements
present opportunities for further improvements in efficiency and sustainability. However, challenges such as the need
for more sustainable materials, improved recycling processes, and the adaptation to evolving regulatory landscapes
remain. The growing demand for electric vehicles and renewable energy systems also offers a significant opportunity
for the development of innovative electric motor technologies.
For industry leaders, continuous investment in research and development is essential for developing more efficient and
sustainable electric motors. Embracing circular economy principles in motor design and manufacturing can also
contribute to sustainability goals. Policymakers should focus on creating and updating regulations that encourage
innovation in sustainable motor technologies and provide clear guidelines for efficiency and environmental
performance. Collaboration between industry, academia, and government is crucial for advancing sustainable practices
in electric motor development.
The study underscores the importance of sustainable electric motor design in the context of global environmental and
energy challenges. Future research should focus on exploring new materials and technologies to further enhance motor
efficiency and sustainability. The development of standardized methods for assessing the environmental impact of
electric motors throughout their lifecycle is also recommended. Additionally, research into effective recycling and
maintenance strategies will be crucial for promoting the circular economy in electric motor manufacturing and use. As
the field continues to evolve, ongoing research and collaboration among stakeholders will be key to realizing the full
potential of sustainable electric motor technologies.
Compliance with ethical standards
Disclosure of conflict of interest
No conflict of interest to be disclosed.
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