Originally Posted by bmentink
I would like to see what it is going to cost here in New Zealand, might pay a visit to ABB down the road from my work ..
Yes, do. If that fails, you might like to contact David Gayner of Control Logic, Australia. It seems from a review of old email that he was instrumental in getting the motor ordered.
[ Edit: It was David Gayner that visited us; here are his details:
David Gayner : : Automation and Drives Sales
Control Logic Pty Ltd
T: 07 3623 1212 D: 07 3623 1231
F: 07 3623 1211M: 0409 626 817
He's based in Brisbane, as are Dave and I (Weber and Coulomb on the AEVA and here). ]
[quote] So when you ordered the motor, did you specify the voltage as 240vRMS DELTA connection and a 132 size case?
The 132 frame size is part of the motor part number. Here are the numbers from the catalogue, along with numbers for a few other motors you might want to look at:
However, the motor voltage is an option, so you need to specify the complete part number:
3GAA 131 008-HSE
The 3GAA is just aluminium motors. The "13" part means 132 frame size; the "1" means one pole pair (2-pole). We went for a 2-pole motor as its speed matches an ICE better when using a car transmission. However, if you want to overvoltage/overfrequency to the max, then you might want to consider a 4-pole motor (more torque, less base speed). The "008" is this particular 22 kW motor, high output and all that. I forget what the "H" option is; I think it's the large flange. The "S" option (in HSE) is the important one for the voltage: it means 400 V Star (of 230 V delta). I also forget what the "E" means; look up the ABB catalogues for details. [Edit: looks like it's also part of the full motor part number; perhaps the "E" implies "high output design", or something. ]
I take it they have to do a special wind for that voltage ..
Well, I think that any motor that's somewhat unusual like this is a special order. I don't know if the "S" option made it take longer or not. Note: it took us about 9 months from order to receiving the motor (and then it arrived with the wrong flange; the flange is a standard part and ABB corrected it quickly... twice, if I recall).
Also, these high output motors don't meet the Australian MEPs efficiency requirements, but there are exemptions for use in vehicles. Check with ABB as to whether a similar thing happens with your country. We just had to send a letter quoting the law, and declaring that the motor was for use in a vehicle, and is therefore exempt. That delayed our order a few weeks as well.
do you think you will have to add any forced air cooling, or does the motor have that built in ...
All induction motors that I know of come with an impeller at the end for cooling. This is fine when running at 50 Hz or 60 Hz all day, but in a vehicle, a motor gets hottest when accelerating, a lot of which is at low speed. So you get too much cooling when cruising, and not enough when accelerating, and none while waiting at lights after doing a lot of work. So we've removed the impeller fan, and will probably use the shaft that is thereby exposed to put on a pulley to run the air conditioner, and perhaps the power steering (it was also going to run the alternator, but we found suitable high voltage power supplies to act as DC/DC converters).
We suspect that the motor will be loafing and not need any cooling, when it's run with a 900 V controller. However, with a 450 V controller (all that is available right now), we'll be running at lower RPMs and higher torque, therefore higher current, so we expect we'll need a thermatic car fan (designed for radiators) to cool the fins. We have a thermistor in the motor (required for the Tritium controller) that will give us an idea of the motor temperature.
Note also that the Tritium requires a shaft encoder on the motor, so that's another minor expense and installation. It won't run open loop as some other controllers will. It's probably a good idea to install an encoder even if it's optional, to get the most out of the motor.
what was the weight of the motor?
As you can see above, 95 kg. Not exactly a brute, but not light either. There is a lot of copper and iron packed into that compact frame; see our build thread for photos.
[ Edit: compare for example with Acmotor's (the avatar's) motor, which is also 22 kW nominal, and 2% more efficient, but in a 180 frame (!), and weighs 161 kg! ]