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a motor for VESC !!

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themotorman
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a motor for VESC !!

I have designed and built a motor using completely new design features, It is unusually efficient and lightweight. I designed it for my 3 wheel car ( motorcycle in USA ). The motor weighs only 16 KGs and can deliver 100 HP at over 95% efficiency at 5000RPM. I would be pleased to put the design out for open source if anyone is interested, Currently I need a controller to run the motor at full power as my current one only handles about 25 HP. The motor is designed to run with a 400 volt supply, kV is 20rpm/volt. It is a 3 phase PMAC using Hall cells but an encoder could be added. The output back emf is a poor sinewave so I use a trapezoidal drive. The advantage of this motor is it is lightweight and has very high efficiency allowing for forced air cooling. It would be ideal for a light plane. Any interest either with providing a controller or building yoour own motor, I can supply any custom machined parts at cost. THe design is scalable for those not needing such high power.

Thank you. Themotorman

lizardmech
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Sound's interesting, what is the layout and general design of the motor?

TechAUmNu
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Likely an axial flux motor. Typically get about 100-400HP in 20kg.

https://www.magnax.com/magnax-blog/a-new-generation-of-axial-flux-ev-motors

lizardmech
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I was thinking this as well, might be a coreless one as he was asking about high ERPM in another thread.

themotorman
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FYI  The motor is an axial, correct. However the phases are not together, each has its own rotor and winding. This means that the interconnections in a phase are minimal very low Rm.. Also use amorphous iron for very low loss. It is compact only 6 x 6 x 12 inches . max RPM with current design is about 15,000 with a 100% calculated safety margin. The windings can be easily changed for other motor constants.  It is currently forced air cooled in my car but future iterations will be liquid cooled, mostly 'cause I dont like the blower noise but also liquid cooling is far more controllable than forced air. You can move the heat source where ever you like.. my friend says put is under their seat!! The construction is simple (now!!) and custom parts are all drawn in 3D software for either CNC or 3D printing. The coils are pre-wound ready to be attached and epoxied in place.  Once I have all  the pieces assembly is about 6 hours, no special tools needed, but assembly procedure must be followed as magnets are plenty strong enough to more than impress you. 

BTW I haven't heard from the 400 volt 350 amp guys... where are they, who are they? 

themotorman

TechAUmNu
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Sounds really good :D what is the output power on that one? How big/heavy would it be if scaled down for about 20-30kW?