Systematic Digital Twin-Based Development Approach for Holistic Sustainable Electric Traction Motors

Johannes Scholz (), Nicolaus Klein, Florian Kößler and Jürgen Fleischer
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Johannes Scholz: Institute of Production Science, Faculty of Mechanical Engineering, Karlsruhe Institute of Technology (KIT), Kaiserstrasse 12, 76131 Karlsruhe, Germany
Nicolaus Klein: Institute of Production Science, Faculty of Mechanical Engineering, Karlsruhe Institute of Technology (KIT), Kaiserstrasse 12, 76131 Karlsruhe, Germany
Florian Kößler: Institute of Production Science, Faculty of Mechanical Engineering, Karlsruhe Institute of Technology (KIT), Kaiserstrasse 12, 76131 Karlsruhe, Germany
Jürgen Fleischer: Institute of Production Science, Faculty of Mechanical Engineering, Karlsruhe Institute of Technology (KIT), Kaiserstrasse 12, 76131 Karlsruhe, Germany

Sustainability, 2025, vol. 17, issue 6, 1-24

Abstract: Sustainability is a key challenge today. The high emission impact of the mobility sector requires a shift from internal combustion engines to electric traction motors. In order to improve sustainability holistically, the entire lifecycle from raw materials, manufacturing, use and end-of-life must be considered during development. Although a lot can be carried out to influence sustainability during the development phase, knowledge about the product is still very limited. Considering the main lifecycle stages already during the development phase requires a systematic development approach. Furthermore, integrating data from previous product generations is required. Generating a digital twin which collects data over the lifecycle is a useful tool which enables the prediction of evaluation criteria for the lifecycle stages. However, when using the digital twin, a suitable description model needs to be generated. A cross-lifecycle evaluation model based on Life Cycle Costing (LCC) and Life Cycle Assessment (LCA) was used to evaluate sustainability throughout the whole lifecycle. Information for evaluation was generated using a cross-lifecycle modeling approach, which enabled the combination of different lifecycle perspectives during development. To show the potential of evaluating different solutions from different perspectives, the methodology was demonstrated with a lightweight rotor of an electric traction motor. The great potential of the process model is shown.

Keywords: digital twin; sustainable manufacturing; electric traction motors; electric mobility; sustainable development process (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2025
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