EMRAX 188 Bedienungsanleitung
www.emrax.com
User’s Manual for Advanced Axial Flux
Synchronous Motors and Generators
User’s Manual for Advanced Axial Flux Synchronous Motors and Generators
www.emrax.com Version 4.5 / January 2017 2
Contents
1. Technical data of EMRAX motors................................................................................................................................................ 7
EMRAX 188 Technical Data Table............................................................................................................................................. 12
EMRAX 208 Technical Data Table (dynamometer test data)..................................................................................................... 13
EMRAX 228 Technical Data Table (dynamometer test data)..................................................................................................... 15
EMRAX 268 Technical Data Table (dynamometer test data)..................................................................................................... 17
EMRAX 348 Technical Data Table............................................................................................................................................. 21
2. Intended usage of the EMRAX motor/generator ...................................................................................................................... 22
3. Motor types and additional motor parts................................................................................................................................... 22
4. Order codes, tariff (HTS) codes, weights of EMRAX motors and additional motor parts........................................................... 25
5. 3D drawings of EMRAX motors................................................................................................................................................. 27
6. Mounting the motor................................................................................................................................................................. 27
7. Power/torque transmission and shafts..................................................................................................................................... 28
8. Controlling direction, position and rotation speed of EMRAX motors ....................................................................................... 33
9. Suitable controllers for EMRAX motors .................................................................................................................................... 38
10. Two same sized EMRAX motors connected serially (EMRAX TWIN) –stacking capability of EMRAX motors ........................... 40
11. Redundancy ........................................................................................................................................................................... 42
12. EMRAX motor working as a generator and its integration into the hybrid system .................................................................. 43
13. EMRAX motor ingress protection (IP CODE)............................................................................................................................ 43
14. Motor cooling......................................................................................................................................................................... 44
15. EMRAX motor materials, quality and reliability ...................................................................................................................... 46
16. EMRAX motor bearings and life expectancy ........................................................................................................................... 47
17. EMRAX motors as in-wheel motors ........................................................................................................................................ 49
18. Maintenance and protection of EMRAX motor against environmental disturbances .............................................................. 49
19. Starting EMRAX motor (connecting the motor with controller): ............................................................................................. 50
20. How to choose the correct EMRAX motor type for every application: .................................................................................... 52
21. Usage of EMRAX motors for electric vehicles (EV) ................................................................................................................. 53
How to calculate power and torque for EV?............................................................................................................................. 53
Mounting options of EMRAX motor for electric car:................................................................................................................. 54
Example of calculation for electric Audi ETT:............................................................................................................................ 55
22. EMRAX Certificates................................................................................................................................................................. 56
23. EMRAX disclaimer .................................................................................................................................................................. 56
24. Service.................................................................................................................................................................................... 57
User’s Manual for Advanced Axial Flux Synchronous Motors and Generators
www.emrax.com Version 4.5 / January 2017 3
Table of Figures
Figure 1: EMRAX testing at Letrika d.d. Company ........................................................................................................................... 6
Figure 2: Scheme of EMRAX motor................................................................................................................................................. 6
Figure 3: EMRAX 188 drawing ........................................................................................................................................................ 7
Figure 4: EMRAX 188 (IP21)............................................................................................................................................................ 7
Figure 5: EMRAX 208 drawing ........................................................................................................................................................ 8
Figure 6: EMRAX 208 (IP65)............................................................................................................................................................ 8
Figure 7: EMRAX 228 drawing ........................................................................................................................................................ 9
Figure 8: EMRAX 228 (IP21)............................................................................................................................................................ 9
Figure 9: EMRAX 268 drawing ...................................................................................................................................................... 10
Figure 10: EMRAX 268 (IP21)........................................................................................................................................................ 10
Figure 11: EMRAX Very High Mechanical Loads (VHML) drawing. EMRAX VHML Low Voltage needs doubled phase connectors
(2xUVW). ..................................................................................................................................................................................... 10
Figure 12: EMRAX 348 drawing .................................................................................................................................................... 11
Figure 13: EMRAX 348 (IP65) with encoder .................................................................................................................................. 11
Figure 14: Mounting holes on front and back side of the motor ................................................................................................... 27
Figure 15: Mounting options (air propeller / in-wheel)................................................................................................................. 27
Figure 16: X shape brackets for EMRAX motors............................................................................................................................ 28
Figure 17: EMRAX transmission shafts.......................................................................................................................................... 29
Figure 18: Standard motor shaft vs. extended shaft with outer splines (ESO) ............................................................................... 30
Figure 19: ESO and FSI.................................................................................................................................................................. 30
Figure 20: Standard motor shaft vs. EMRAX 268 VHML shaft ....................................................................................................... 30
Figure 21: FSI................................................................................................................................................................................ 30
Figure 22: EMRAX with ESO and FSI.............................................................................................................................................. 31
Figure 23: Power/torque transmission from front motor side ...................................................................................................... 31
Figure 24: Power/torque transmission from front (FSI) and/or back motor side (ESO) ................................................................. 32
Figure 25: Power/torque transmission from front motor side to the transmission gear ............................................................... 32
Figure 26: Motor with extended shaft from back motor side........................................................................................................ 33
Figure 27: Resolver / encoder on back motor side....................................................................................................................... 34
Figure 28: Resolver / encoder on front motor side ....................................................................................................................... 35
Figure 29: Encoder with bracket................................................................................................................................................... 35
Figure 30: Resolver with bracket .................................................................................................................................................. 35
Figure 31: EMRAX with hall sensors.............................................................................................................................................. 36
Figure 32: Motor phase connectors –normal (UVW) and doubled (2xUVW) ................................................................................ 37
Figure 33: EMRAX TWIN drawing ................................................................................................................................................. 40
Figure 34: EMRAX TWIN with encoder ......................................................................................................................................... 41
Figure 35: EMRAX TWIN with tandem resolver............................................................................................................................. 41
Figure 36: Coolant fittings for EMRAX TWIN................................................................................................................................. 41
Figure 37: EMRAX TWIN shafts –ESO is mounted in the first motor and FSI on the front side of the second motor ..................... 42
Figure 38: Motor with extended shaft and flanged shaft on the extended shaft (for EMRAX TWIN) ............................................. 42
Figure 39: EMRAX IP21................................................................................................................................................................. 43
Figure 40: EMRAX IP65................................................................................................................................................................. 44
Figure 41: Motor cooling options ................................................................................................................................................. 44
Figure 42: Motor coolant fittings for one motor ........................................................................................................................... 45
Figure 43: Combinations of bearings for EMRAX motors .............................................................................................................. 47
Figure 44: Pull-push (PP) bearing outer ring fixation..................................................................................................................... 49
Figure 45: Straight connection of motor phase connectors to controller cables. .......................................................................... 50
User’s Manual for Advanced Axial Flux Synchronous Motors and Generators
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Figure 46: Angular connection of motor connectors to controller cables. Connections must be isolated with shrink hose!.......... 51
Figure 47: Isolation of electrical phase connectors with shrink hose ............................................................................................ 51
User’s Manual for Advanced Axial Flux Synchronous Motors and Generators
www.emrax.com Version 4.5 / January 2017 5
Dear Customer,
Congratulations on your purchase of the EMRAX high performance electric motor.
This drive is a Slovenian product of a completely new type of pancake axial flux synchronous permanent magnet electric motor,
which will keep its capability for a long time if treated properly. It can also work as a generator with the same performance
characteristics. The drive was developed for airplanes, where reliability is extremely important. Therefore, our target was to
build a reliable, low weight, high power direct drive electric motor with high efficiency.
The drive was developed and tested by Roman Sušnik, dipl. ing. (Company EMRAX d.o.o., till March 2016 company name was
Enstroj d.o.o.). The first prototype was mounted onto the glider airplane Apis EA2 in 2008, when also the 1st electric flight in
Slovenia and the 3rd in the world was made. The motor was also laboratory tested in Piktronik d.o.o (January 2011), Siemens
GmbH (May 2012) and Letrika d.d. (November 2014). Furthermore, our customers give us test results from their projects to
confirm our test data. In February 2014 thermal tests were performed on EMRAX motors. The motor was exposed to shock tests
from -40°C to +160°C for 17 days (24h/day), this means 408 hours non-stop. EMRAX passed this examination with excellent
results, without any damages.
Meaning of EMRAX name:
- EM stands for the Electric Motor,
- R is the first letter of the innovator’s name, who is Roman
- AX stand for the axial magnetic flux
EMRAX motor features:
- Axial Flux
- Permanent magnet synchronous motor
- Input type: sinusoidal three phase
- Lightweight - best in class power density (up to 10 kW/kg)
- High torque at low RPM
- Highly efficient (up to 98%)
- Reliable (developed and produced for the airplane industry)
- Compact and high-quality product
- IP21 or IP65
- EMC Compliant –E marked (complies with essential protection requirements of 89/336/EEC)
- Low cost
- 3 Cooling options (Air/Liquid/Combined)
- Low noise
- No vibrations
- Stacking capability (two same sized motors connected on the same shaft)
The EMRAX engine can achieve high power even at relatively low rotation speeds due to high torque. It allows a gearless drive
without the usual step-down gear unit which causes power losses, additional weight, complexity and maintenance. In the case
where the lower output rotation is needed the reduction drive can be used, which allows even higher torque (power stays the
same).
The EMRAX motor ranks as the best high power density motor in the global market. Its power density is very high –up to 10
kW/kg. EMRAX motors have the best-in-class power density. The mechanical and no load electrical loses are very small, so
EMRAX can run on high RPM –in which case very high motor power can be achieved (up to 300 kWp –e.g. EMRAX 348 type).
EMRAX motors use less material more efficiently to provide higher power densities than any comparable motor or generator.
Though many intensive tests have already been made and despite the parts being produced by modern CNC machines, the
motor is still not a real series product. Many manufacturing processes are still made by hand, which makes every drive unique.
Therefore, our customers are and will be part of the field test, thus we are already excited about the experiences they will make
with the new motor.
User’s Manual for Advanced Axial Flux Synchronous Motors and Generators
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EMRAX engines have been sold since the year 2008. Through the years of experiences we have made many improvements. The
development is a never ending story, therefore improvements will still be made. The customer assumes responsibility to share
the experiences made with the drive with the manufacturer, in order for the manufacturer to gather the know-how and identify
possible weaknesses.
The usage of EMRAX motors is in automotive, motorsport, off road, marine, industrial, aerospace applications.
The orders are rising monthly, consequently we are prepared to raise the production quantity by multiplying the existing
production cells and also start mass production. Even though motors are not made in high volumes, the advanced materials and
proprietary construction techniques enable significant customer cost benefits. Therefore EMRAX motors have a very competitive
price in their class.
Applications where EMRAX motors can be used:
- Traction motors for on, off-road, rail and marine transport (hybrid or full electric).
- Generators (especially where size and weight are important).
- Integrated starter Generators (ISG) (start, generate and power boost from a small volume).
- Hydraulic replacement (compact and efficient alternatives for hydraulic motors and starters).
Figure 1: EMRAX testing at Letrika d.d. Company
Figure 2: Scheme of EMRAX motor
User’s Manual for Advanced Axial Flux Synchronous Motors and Generators
www.emrax.com Version 4.5 / January 2017 7
1. Technical data of EMRAX motors
EMRAX motors/generators are advanced axial flux synchronous (BLAC) electric motors/generators. EMRAX motors are
available in a range of torque and speed combinations and with variety of cooling options. EMRAX motor types (the number in
the name means the diameter of the motor in mm):
EMRAX 188: is being developed. It will be available for sale at the end of 2016. Orders are being collected.
- High Voltage (Air Cooled / Liquid Cooled (IP65) / Combined Cooled (IP21)
- Medium Voltage (Air Cooled / Liquid Cooled (IP65) / Combined Cooled (IP21)
- Low Voltage (Air Cooled / Liquid Cooled (IP65) / Combined Cooled (IP21)
Figure 3: EMRAX 188 drawing
Figure 4: EMRAX 188 (IP21)
EMRAX 208: In production.
- High Voltage (Air Cooled / Liquid Cooled (IP65) / Combined Cooled (IP21)
- Medium Voltage (Air Cooled / Liquid Cooled (IP65) / Combined Cooled (IP21)
- Low Voltage (Air Cooled / Liquid Cooled (IP65) / Combined Cooled (IP21)
User’s Manual for Advanced Axial Flux Synchronous Motors and Generators
www.emrax.com Version 4.5 / January 2017 8
Figure 5: EMRAX 208 drawing
Figure 6: EMRAX 208 (IP65)
EMRAX 228: In production.
- High Voltage (Air Cooled / Liquid Cooled (IP65) / Combined Cooled (IP21)
- Medium Voltage (Air Cooled / Liquid Cooled (IP65) / Combined Cooled (IP21)
- Low Voltage (Air Cooled / Liquid Cooled (IP65) / Combined Cooled (IP21)
User’s Manual for Advanced Axial Flux Synchronous Motors and Generators
www.emrax.com Version 4.5 / January 2017 9
Figure 7: EMRAX 228 drawing
Figure 8: EMRAX 228 (IP21)
EMRAX 268: In production.
- High Voltage (Air Cooled / Liquid Cooled (IP65) / Combined Cooled (IP21)
- Medium Voltage (Air Cooled / Liquid Cooled (IP65) / Combined Cooled (IP21)
- Low Voltage (Air Cooled / Liquid Cooled (IP65) / Combined Cooled (IP21)
*Customisations: EMRAX 268 Very High Mechanical Loads (VHML)
User’s Manual for Advanced Axial Flux Synchronous Motors and Generators
www.emrax.com Version 4.5 / January 2017 10
Figure 9: EMRAX 268 drawing
Figure 10: EMRAX 268 (IP21)
Figure 11: EMRAX Very High Mechanical Loads (VHML) drawing. EMRAX VHML Low Voltage needs doubled phase connectors
(2xUVW).
Andere Handbücher für 188
1
Dieses Handbuch passt für folgende Modelle
4
Inhaltsverzeichnis
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