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Companies of PMSM electric motor

20K views 39 replies 6 participants last post by  muffildy  
#1 ·
Hello !

I'm new on this forum and I will introduce the project that my team and I have planed for this year. We are building an electric single seat racing car to compet in Formula Student (FS) Challenge : http://www.formulastudent.com/default

We decided to use a AC Permanent Magnet Synchronous Motor for our vehicle, but i encounter some difficulties to find the appropriate one.

The specifications of the motor that we would like is :

- Peak power : 60kW maximum (FS rules)
- Maximum voltage : 400V (FS rules)
- Maximum weight : 25kg
- Peak torque (used during 5 to 10 seconds max) : approximatly 140 to 200 Nm
- Peak motor speed : minimum of 5000rpm

Car characteristics:
- Max car weight : 310kg ( 683lbs)
- Peak longitudinal acceleration : 0.85g – 1g (g=9.81m/s²)
-Wheel diameter : 2*0.254 meters
- Max speed : minimum 110 km/h
- Max torque on rear tires : 750 to 850Nm

To obtain this torque on the wheels, we will use a reducer.

We are limited for the battery capacity to a maximum of 7250 Wh and a voltage of 400V.


My main problem is that i can't find a such motor, except only one, the Mavilor MA-55 :

http://www.mavilor.es/pdf_products/ma_series.pdf

This motor has great performances :
- 16.8kg
- max speed : 6000 rpm
- peak torque : 190Nm

If we plan a car top speed of 130km/h (142rad/s with a 0.254m half wheel diameter), we obtain with a reducer of 4.42, a peak torque on rear wheels of 842Nm that matches perfectly !

However, we can't get in contact with this company, so we have to find another electric motor, but we don't find any one that correspond completly to all of our characteristics (especially the weight !)

Here is a list of all other motor that we found, but are twice the weight we limited for the motor :

Baumueller DSD100
Boschrexroth MSK101D-0450
Boschrexroth MSK101E-0200
Boschrexroth MSK101E-0300
Boschrexroth MSK101E-0450
SEM HR190J8-180S
SEM HJ190K8-180S
EVE M2-AC15/4-AS/L
Evo electric AFM-140
Brusa ASM6.17.12


Thus, I would like to know if you know any company which produce such kind of motors ?

I already have a look in the forum, but i didn't find what me and my team need for our project...

Thank you,

Fabien
ESTACA Eco Racing Team
 
Discussion starter · #5 ·
What rules are you looking at? I am also a member of a team looking to compete in Formula Student electric, the rules for the 2012 competitions are:

600V max
85kW max

Since the peak power is higher I would recommend using AFM-140. While it does weigh more, you can use a very low reduction ratio (1.5:1 say) and get amazing torque off the line. Since you are limited to 85kW battery current,

85kW / 650 nm = 130 rads/sec / 1.5 gear ratio = 87 rads/sec

87rads/sec / 142rads/sec * 130km/hr = 80km/hr

You should be able to get 1+ g of acceleration until 80km/hr, with a car weight of 400kg or less. While it might be over the weight of the motor, I think in this case you may want to just go for something heavy but powerful.

Also, much higher top speed than 130 km/hr, although I understand this is not important as the race is mainly lower speed tight corners.
Hi charliehorse55,

Yes the rules changed since I posted this thread on the forum. In fact our team was looking at rules that was supposed to be applied for 2012 (400V 60kW) but they finaly didn't choose those rules.

Thank you for your help ! Well, I know that the AFM-140 is great for his high torque, but we won't use all its performance because the battery is limited to deliver at maximum 85kW, and this motor can be used at a peak power of 167kW for 60s, but it won't be possible because of the battery limitation power. If i resume, with this motor we will use it for maximum at the nominal values, which mean that we embark aboard the car a high weight motor which won't be use at its best performances. That's why i was trying to find motor with a lower weight than this one, and that can be adapt to the power required for the car ! Please tell me if my reasoning is wrong, maybe i'm doing wrong since the biginning !


Fabien