I'm sorry if this offends some people on this channel, but I am developing a new kind of internal combustion engine (Avadi engines), and am working to integrate a starter generator system. The issue is that due to our unique crank architecture, the output shaft RPM is 1/2 speed of a normal engine. This application would be for a hybrid powered drone. I am having trouble locating any smaller scale AF motors that would be in the neighborhood of performance needs. I really don't want to develop one if there is something available already. As I am focused primarily on engines, perhaps there is a better way to do this than an AF. Open to changing course.
specs:
Motor Type: Axial flux permanent magnet synchronous motor (PMSM) or brushless DC motor (BLDC), coreless design preferred to reduce cogging torque and improve efficiency.
specs:
Motor Type: Axial flux permanent magnet synchronous motor (PMSM) or brushless DC motor (BLDC), coreless design preferred to reduce cogging torque and improve efficiency.
- Power Rating: Continuous 5-15 kW (peak up to 20 kW if needed for bursts).
- Voltage: Nominal 48V DC (options for 72V or 96V if higher power is required; confirm compatibility with battery/electronics).
- RPM Optimization: Base speed 1000-2000 RPM (for maximum torque); efficient operation up to 3500-4000 RPM peak. Please adjust from low-RPM base models via custom windings/pole count.
- Torque Requirements: Peak torque 50-200 Nm for cranking/starting (to overcome engine compression at 0-500 RPM); continuous torque 20-50 Nm for regeneration/assist.
- Efficiency: >90% across operating range, especially in generator mode for energy recovery.
- Dual-Mode Functionality: Bidirectional operation—motor mode for starting, generator mode for regeneration. Please recommend a compatible bidirectional controller/inverter.
- Dimensions and Mounting: Compact disc-shaped design (e.g., diameter <200mm, axial length <100mm) for direct output shaft mounting. Provide shaft details: e.g., shaft diameter (measure yours, say 20-30mm), spline/keyway type, and any flange/mounting hole patterns.
- Cooling: Air-cooled with fins (to match engine aesthetics) or liquid-cooled for high-duty cycle.
- Other Features: IP54 or higher protection rating; low noise/vibration; aluminum housing for lightweight; CE/ISO certification if possible.
- Quantity and Timeline: Prototype quantity 1-5 units; customization lead time target 2-4 weeks.
