Thread: Pan cake motor
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Old 01-16-2015, 01:27 PM   #4 (permalink)
JRMichler
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Join Date: Feb 2011
Location: Phillips, WI
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Nameless - '06 GMC Canyon
90 day: 37.45 mpg (US)

22 Maverick - '22 Ford Maverick XL
90 day: 41.61 mpg (US)
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A few random tips if you are designing a motor:

1) End turns add weight and resistance. Minimize them.
2) Use thin laminations of high permeability electrical steel for the magnetic circuit. Low stress machining, properly deburr.
3) Balance the magnetic circuit between steel and copper. Pole iron area, copper area, and back iron.
4) Minimize voltage between adjacent wires. Especially important between phases.
5) Enough electrical insulation to handle the peak voltage at that point. Don't forget switching transients.
6) Consider the effect of thermal stresses in the insulation system. This is one of the biggest motor killers.
7) Design frame for peak mechanical loads.
8) Minimize rotor / stator gap. Take into account ALL machining tolerances, assembly tolerances, thermal expansion, and deflections under load.
9) There's a lot more......

I have worked on motor development. Building a motor good enough to drive a vehicle is a much bigger job than it looks like at first glance.
__________________
06 Canyon: The vacuum gauge plus wheel covers helped increase summer 2015 mileage to 38.5 MPG, while summer 2016 mileage was 38.6 MPG without the wheel covers. Drove 33,021 miles 2016-2018 at 35.00 MPG.

22 Maverick: Summer 2022 burned 62.74 gallons in 3145.1 miles for 50.1 MPG. Winter 2023-2024 - 2416.7 miles, 58.66 gallons for 41 MPG.
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