Tesla carbon wrap rotor teardown

[speedmd]

Sandy Munro tears down a new Plaid motor. Interesting looking internal magnet rotor design with a isolated pole cap and carbon wrap. https://youtu.be/4lGVimLK58g?t=1043

 

[SafeDiscDancing]

So they went with this design huh?

Interesting... very interesting...

 

[speedmd]

What would Rorschach suggest? :lol:

Better view of of the assembly.

 

[liveforphysics]

3pole pairs or 6 N/S poles. 8 poles would have excessive electrical frequency core losses at >200mph, but 4 pole pairs gets heavier and more difficult to distribute flux to the edges, and torque ripple increases. That spoked hub structural topology is similar to the Zero IPM rotor structure, but scaled to match the 6 pole design.

They did a great job with the IPM segments not having shorted linking iron through the use of the carbon shell.

Im so grateful to be powered by three of these fine motor rotors on every driving trip I make.

 

[mxlemming]

The shape of the rotor on the Tesla one is heavily optimised to have large flux paths (low magnetic resistance, high inductance) 90 electrical degrees to the permanent magnets flux paths. This makes it able to generate a lot of reluctance torque and be more effective in the field weakening regime.

The triangles cut out making it look somewhat star like are there to reduce the flux path through the magnets to the complimentary pole and back out to the stator. Effectively, this improves the LdLq ratio.

It's a lovely design. The not carbon wrapped concept has been around for a while though/ and carbon wrapping of rotors was being fling around when I was at uni in 2006...



The zero motor although superficially spoked, does not appear to have anything like the same magnetic circuit intention. It appears at first glance that the zero motor is optimising torque production vs weight, whereas the Tesla one is optimising more for extended speed operation. Both valid goals in their respective application.

 

[speedmd]

Interesting use of the back iron, by wrapping the pole center and extending it up to the gap with roughly a equal flux path section. Would love to see the flux dynamics on it. Main hex section with squared off-extended points massing reminds me more of a sheriffs star with a big hole in the center.

 

[speedmd]

3pole pairs or 6 N/S poles. 8 poles would have excessive electrical frequency core losses at >200mph, but 4 pole pairs gets heavier and more difficult to distribute flux to the edges, and torque ripple increases. That spoked hub structural topology is similar to the Zero IPM rotor structure, but scaled to match the 6 pole design.

They did a great job with the IPM segments not having shorted linking iron through the use of the carbon shell.

Im so grateful to be powered by three of these fine motor rotors on every driving trip I make.

Took a peek at this vid for a bit of one going its paces on track. WOW. Sweet ride my friend!
https://www.youtube.com/watch?v=Ujp3q_aryRA