Permanent Magnet(PM) Brushless Motors for Electric vehicles are an increasing attention subject for all automotive OEMs with advent of new paradigm in green transportation.  Rare-Earth PM BLDC motor is such a new energy saving electrical machine, which has the merits of small volume, light weight, high efficiency, low rotary inertia, highly control precision and so on.

We at TSUYO, design and develop all kind of motors and controllers with specific parameters and attributes according to the end usage pattern and driver behaviour. Our Products are also easy to service and monitor. We finalize our products’ BOM based on several re-engineering, benchmarking and supply chain feasibility way. Our motors’ durability and efficiency are key highlights to look for.

With the help of our European technology partner who are already into this motor business through designing, developing, manufacturing and selling for more than 30years, we present our different application based BLDC motors and controllers for our target customers. Firstly, the performance indicators of our motors are determined in line with the power requirements of the E-Vehicle at different driving speed and then followed by choosing the right Air-Gap length, Permanent magnet Thickness and the no. of stator winding turns as variable and subsequently parametric analysis is made to check the in-turn influence of structural parameters on system efficiency and torque –current ratio. Post doing all kind of lab iteration, an optimized design based prototype is built and extended for testing in-house as well as at customer’s end to check whether the prototype meets the need of the driving system, both in constant torque region and constant power region.

We do consider the interior magnetic structure compared to the surface magnetic structure as intrinsic values are more reliable with higher mechanical strength and better anti-demagnetization ability and extend the better field-weakening operation area.

The preliminary design of IPM-BLDC Motors considers various parameters judiciously like outer diameter of stator, inner diameter of stator, air gap length, no. of stator slots, dimension of stator slots, tooth width, no. of parallel branches, no. of conductor per slot, outer diameter of rotor, inner diameter of rotor, core length, thickness of magnet, width of magnet, mechanical pole embrace, width of magnetic bridge, length of magnetic bridge etc.

key BOM picture is shown below for reference

Our Design Approach For All OEMs Mainly Focus Based On Below Philosophy

FEW REFERENCES performance and efficiency highlights