Project FT00 - A compact 125V 30kW motor with 6.77 planet output

djsftree

1 mW
Joined
Nov 18, 2020
Messages
15
Early 2021 I started designing a reasonably priced compact motor with a planetary output.
At every stage things just got more complicated and required another month or so of learning.
Then life started again and development slowed once more.

Stay tuned!

Thanks @DanGT86 for suggesting a new thread here in Motor Technology

My initial parallel paths / goals from 2021

Proposed Motor
Stator 110mm dia, 110mm long
NO20 (with Suralac 9000) lasercut & bonded laminations
10 pole N45SH
Continuous power 30kW @ 10,000 rpm
Peak power 50kW for a seconds
Optimised stator water cooling gallery jacket

Proposed gearbox
Gearbox lifetime - 7500 hours nominal torque
Target gear train ratio approx 6.5
No hunting teeth allowed
Difference between dominant orders in the drive system min 8 Hz
Teeth designed to minimize sliding friction and wear
Teeth contact temperature target < 110 C
Teeth geometry can be manufactured by using standard module tooling
Safety targets - root > 1.3, flank > 0.9, scuffing > 2.0
Teeth total contact ratio target 3.1
Gear geometry is designed for better noise, vibration, and harshness

Proposed mechanical system
Approx 250mm long, 130mm diameter
Under 20Kg

Proposed controller for dual motor control
Renesas RZ/T2M brain board
Dual 2 wire network (EtherCAT?) inferface TJA102A
100M Ethernet header
Isolated CAN interface ISO7721/TJA1042T
Dual motor control interface (6 PWM, 8ch analog input / 3ch delta-sigma input per motor)
Dual multi protocol encoder interface for actual wheel speed monitoring
Onboard battery mangement MAX17841

Proposed power board
No idea yet :)
150V mosfet candidate from the new OptiMOS™ 6 TOLx family looks compelling optimos 6
Ciss/Crss Ratio: ~300 (7500/25)
Rds(on): 2.5mΩ
Gate Charge (Qg): 105nC
Voltage Rating: 150V
Current Rating: 260A

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Ring Gear
I made this on a machine with Y and B axis.
The module 1.0 teeth were "broached" with the B axis tilted and clamped, then using X Y Z and C simulataneous.
I was also able to produce a "crown finish pass" of 6 microns on both side of the tooth by creating an additional multi axis arc path.

I had some initial issues with the tooth path / rigidity when the broach struck the stock.
So I had had to pre-machine a small platform perpendicular to the broach tip.
For proto ring gears it was a lengthy broaching process - about 1 hour but the results are good.

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Over coffee, I decided to create a rotor magnetic field checker.

Header to mount Arduino Nano ESP32 (ABX00083)
8pcs - TCA9548A , each with 8 x A31301 attached
Total of 64pcs A31301EEJASR-XYZ-IC-20

The A31301EEJASR-XYZ-IC-20 is a fancy 3D magnetic position sensor ( +/- 2000 gauss )
Sampling 64 devices in multiple planes could yield an interesting diagram!


1725465991436.png
 
Over coffee, I decided to create a rotor magnetic field checker.

Header to mount Arduino Nano ESP32 (ABX00083)
8pcs - TCA9548A , each with 8 x A31301 attached
Total of 64pcs A31301EEJASR-XYZ-IC-20

The A31301EEJASR-XYZ-IC-20 is a fancy 3D magnetic position sensor ( +/- 2000 gauss )
Sampling 64 devices in multiple planes could yield an interesting diagram!


View attachment 359174
I'll opensource this one. :)
 
96V battery supply.
Need to work on my windings.

star wiring, two turns
10krpm @ 300A per phase = 28Nm
96.2% efficiency
840W stator winding loss
0.092 Nm/A
Ld 0.035 mH
Lq 0.042 mH
L 0.037 mH

no load cogging torque at 0 amps / 1krpm.

FT00-magneo.jpg


FT00-eff.jpgFT00-phase_vol.jpg

FT00-phase_cur.jpgFT00-dq-advance_angle.jpg
 
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Over coffee, I decided to create a rotor magnetic field checker.

Header to mount Arduino Nano ESP32 (ABX00083)
8pcs - TCA9548A , each with 8 x A31301 attached
Total of 64pcs A31301EEJASR-XYZ-IC-20

The A31301EEJASR-XYZ-IC-20 is a fancy 3D magnetic position sensor ( +/- 2000 gauss )
Sampling 64 devices in multiple planes could yield an interesting diagram!

Probably a totally useless tool.
Maybe interesting for school experiments.
Done and ready for peer review prior to sending off to JLCPCB.

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Man... this looks good!! awesome work! outstanding! :bigthumb:
Extracting the heat from that 800w ish winding power loss might be a challenge, i know this from my 20Kw aerouse motor, that is not a easy task. I talked with some guys that do electric F4 racing, and they had success with slow flow liquid cooling, and slow flow was the key, in order for the fluid to have time to absorb the heat and then transfer it in to the heat dissipater (radiator).
PS. it is neat how you guard(not show) your "key elements", from builder to builder you know where to look :cool:
 
Man... this looks good!! awesome work! outstanding! :bigthumb:
PS. it is neat how you guard(not show) your "key elements", from builder to builder you know where to look :cool:
Thanks! I have v2 churning away in the background with some air gaps to control flux. Somewhat improved torque, cogging torque and torque ripple too. And weight saving!
 
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V2 work in progress

Here is single turn star winding data, about 220Kv, with a torque constant 0.52Nm/A ish.

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** updating shortly, coil fill factor was incorrrect.
 
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Here is two turn star winding data, about 105Kv, with a torque constant 0.106Nm/A ish.

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** updating shortly, coil fill factor was incorrrect.
 
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Djsftree please, just à rookie question
I guess you have elaborated some Excel spreadsheets to design your motor.
If you had to design a15Kw continuons power motor with max 5000 rpm, I guess it would not very different from your 30Kw motor running at 10 000 rpm??? But the winding probably???
Thks
R
 
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