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Nd₂Fe₁₄B sintered magnets are used in the drive motors of hybrid, electric and other vehicles. A magnet in which rare earth content is reduced by means of a localized diffusion method has been developed in order to reduce the volume of dysprosium. The distribution of the demagnetization fields in a motor is not uniform, so the necessary coercivity distribution for the magnets was quantified using Computer-Aided Engineering (CAE). Then material specifications of the localized dysprosium diffusion satisfied with this coercivity distribution was determined, and optimal manufacturing conditions including the position of dysprosium diffusion were set. The coercivity distribution in every position of the magnet using localized diffusion method was inspected. As a result, the magnet was satisfied with coercivity distribution demanded by CAE.

This paper presents the development of a motor that was supposed to be adopted in the Kinetic Energy Recovery System for the Formula One world championship 2009 series. KERS can recover and utilize braking energy in the form of power assist, with maximum energy use per lap of 400 kJ and maximum power of 60 kW. This hybrid system is expected to provide benefits such as lap time reduction and straightaway speed gain for overtaking. The motor is required to achieve downsizing, light weight, high power density, wide power band, and high efficiency. This paper describes how the on-board layout, size, and specifications were decided and how the newly developed technologies were applied and test result to confirm enhanced performance.