Elaphe has therefore developed a regime for validating the stiffness and durability of bearings before it will integrate them into the L1500 (or its other in-wheel motors). “The bearing is selected as a function of the wheel loads stemming from the vehicle’s weight, its CoG, wheelbase, track width and maximal lateral acceleration achieved during cornering. The windings have been potted in Elaphe’s custom thermal transfer resins. The company’s motor control software has therefore been developed with a modular and common architecture to enable compatibility with varying inverter hardware, as it expects future advances in inverters to rapidly enable higher switching speeds and therefore further improvements in motor control and efficiencies. As with hairpin stators, compact multiphase wave winding uses thick, pre-deformed ‘bands’ (essentially long, thin rods) of copper, rather than strands or thin sheet-cut tapers, for its conductors. The equipment enables rapid iterations and confirmations of product designs, although the company also cooperates with various institutions around the world for impartial third-party validations and to complement its own efforts. The company has software scenarios (and dedicated test tracks, which would be used for road-proving the motor later on) for driving over potholes, brick roads, speed bumps, embedded rock paths and other surfaces to examine how the motor handles the repeated impacts and harmonic stresses of such use. Elaphe’s in-house winding machines are optimised to apply each subsequent phase of copper with the appropriate force to insert and compact the bands into the stator slots as deep as necessary for the desired packing density and uniformity, without scratching or breaking them. “For instance, even in a 200 kW test system it is unlikely that a 60 kW in-wheel motor could be tested at its rated or peak torque, because of how a supplier’s test benches are built and their corresponding torque-sensing limitations. *Prices are pre-tax. The designs yielded from topological optimisation are then run by an industrial designer, so that they can advise on precise guidelines and limitations regarding how the CAD drawings can be feasibly and accurately reproduced in the real world. LM will build those motors in its Ohio plant, alongside the trucks that will use them. Contact a supplier or the parent company directly to get a quote or to find out a price or your closest point of sale. “These are pretty good diameter wheels, thin but big … “The L1500 motors are therefore simply inserted between the electric [or hybrid] vehicle’s hubs and rims, which makes use of the existing space within the wheel without needing to alter any suspension or steering packaging on the platform,” explains Elaphe’s CTO Gorazd Gotovac. A Better Way To Travel. “As we see it, the expected trajectory of transistor advances is too fast to commit to one specific technology that we can confidently wrap our motors around,” Lampic says. Wherever possible, Elaphe has sought to minimise the L1500’s weight. To help the electric BMW X6 perform the tank turns, Elaphe Propulsion mounted four Elaphe L1500 gearless electric motors to each wheel. ... Small Package, Enormous Power : The Elaphe L1500 In … “These are pretty good diameter wheels, thin but big diameter,” Burns explains. “On the chassis, the environmental and structural loads on the inverter are far lower, and it does not contribute any unsprung mass or thermal constraints there, as it would inside the wheel. “In the early years of developing our in-wheel motor technologies, we used mainly N40UH magnets [which have a maximum working temperature of 180 C] in our prototypes in order to ensure good thermal performance,” Gotovac recalls. We have focuses on fuel cells, measuring equipment and ECUs. Established in 2006 by theoretical physicists Andrej Detela and Gorazd Lampic (now the CEO), its systems incorporate a host of patented and proprietary technologies across mechanics, electromagnetics and other disciplines. To ensure each motor provides precise and reliable performance over its lifetime, regardless of differences between vehicle chassis and complementary parts, Elaphe has a rigorous set of design requirements, simulations and testing processes. By running these load simulations in a generative design process (with a constant stiffness target and through a set of proprietary criteria functions), the numerical software can identify all the geometric qualities necessary for minimising structural stress across the metals of the stator and rotor (while also keeping it lightweight and taking manufacturing constraints into account where possible). “The exact length of each band is customised for the application to achieve the correct voltage balancing in each wire, and by extension the right speed and the torque for the motor, without any detrimental effects on current losses,” Gotovac adds. Four Elaphe L1500 gearless electric motors were mounted on each wheel, giving this first-generation BMW X6 a completely different setup that allowed it to spin just like a tank would, by controlling the way each wheel moves, independently. To accurately predict and assess the motor components’ structural integrity requirements in the face of especially harsh road-induced loads, Elaphe used an SUV to simulate severe braking and cornering scenarios. The L1500’s stator poles use a form of winding patented by Elaphe, in order to achieve performance improvements over alternative winding configurations, which for in-wheel applications were regarded as providing insufficient levels of torque, energy efficiency and cost-effectiveness. For instance, in May 2018, Elaphe Propulsion Technologies Ltd. launched the Elaphe L1500 two-wheeler hub motor. Supplied with the whole system, including a high-power inverter (motor controller) and vehicle powertrain ECU (Powertrain control unit). For broader and closer accuracy of how the bearing will behave over its lifetime, Elaphe then conducts experiments using the Wheel Accelerated Life Test machine (WALT) at the Fraunhofer LBF Institute for Structural Durability and System Reliability in Darmstadt, Germany, with additional similar tests locally on dedicated deflection measurement benches. “The advantage, compared with hairpin stators, is that our overhangs are much shorter, meaning less losses,” Gotovac says. Following static testing, fatigue tests are performed to simulate the effects of multiple loads over the service life of the motor, and to see how many repeated loads the motor could take before its components’ fi nite elements begin showing signs of deterioration. As these overhangs lie outside the stator slots, they do not contribute to motor torque. The L1500 has been subjected to extensive tests and simulations. Most of these segments have high growth potential, and they also benefit from a real four-wheel-drive capability with torque vectoring and brake blending in a compact package.”, Permanent magnet, three-phase synchronous AC motor, External rotor with surface-mounted magnets, Internal stator with pseudo-helical multiphase wave winding, Maximum power output: 113.6 kW at 370 V DC, Continuous power output: 65.3 kW at 370 V DC, Continuous power output with field weakening: 83 kW at 370 V DC, Diameter: 464 mm (fits standard 19 in rims), Axial length: 142.2 mm (hub-to-rim attachment is less). Elaphe uses an SUV test vehicle to simulate severe braking and cornering scenarios, “At each stage of this approach, we have worked on the basis of analytical equations that have afforded us an insight into holistically optimising our motors’ designs and dimensions, to meet a broad envelope of performance and environmental requirements as well as other evaluation criteria.”. “Our multiphase wave winding helps increase the packing density of copper, which reduces current density across the length of the conductor. Go to the Elaphe Propulsion Technologies Ltd. website for more information, See all Elaphe Propulsion Technologies Ltd. products. For instance, Elaphe provides L1500 in-wheel motor that has a peak power of 110 KW, with a speed of 1,250 rpm and can be cooled by using the liquid cooling method. In the first year, the PRODRIVE team has delivered the first vehicle, a converted BMW X6, powered by 4× Elaphe L1500 motors, controlled by Elaphe PCU (Propulsion Control Unit) with a total output of 6000 Nm, 440 kW and an overall impressive acceleration and cornering performance. Order today, ships today. (www.prodrive-electric.com).SOURCE Elaphe Propulsion Technologies Ltd. As a result, the ‘active part’ of the motor – the electric machine with windings and magnets – takes up just 30% of the overall weight, giving it a torque density of 460 Nm/litre, compared with what the company cites as its nearest competitor at 390 Nm/ litre. After examining where the earliest deteriorations appear, the design loop is (where necessary) executed again from the start in order to optimise the chamfers, radii and other small shapes and details of the components before actual fabrication. Moreover, in November 2018, Savic Motorcycles announced a new electric motorcycle model Cafe Racer and will launch it by 2020. LM will build those motors in its Ohio plant, alongside the trucks that will use them. The most powerful (110 kW peak) and compact (fits inside a 19" or larger vehicle rim) direct-drive in-wheel electric motor ever produced, capable of delivering up to 1500Nm of wheel torque instantly. (Earlier post. As Lampic notes, every component in each L1500 must be designed for ‘multiphysics efficacy’, capable of handling many different kinds of thermal, structural and electrical loads. Being Elaphe’s largest and most powerful in-wheel motor yet, the project represented new territory for everyone involved. “So, we must use 20" tires. Lordstown Motors licensed the L1500 in-wheel hub motor from Slovenian tech company Elaphe Propulsion Technologies. Examples of these are thermomechanical stress due to excess heat from electromagnetic losses in the copper windings, steel laminations and permanent magnets, and frictional losses in the bearings and seals. “We have patented this approach, and since then some major OEMs have adopted helical multiphase wave winding, but we’ve kept developing our automated winding machinery and stator testing procedures. Second, the cooling system is positioned in such a way that it also intrinsically shields the electromagnetic part from heat transfer from the brakes.”. As a result, Elaphe’s development models encompass an extensive number of studies, simulations and tests, to iterate a motor that will withstand a broad spectrum of loads over its lifetime. 370 VDC nominal voltage. Having been filtered through the industrial designer’s guidelines, the stator and rotor designs are then evaluated (together with connected structural interfaces for a holistic motor simulation) using multiphysics fi nite element analysis (FEA) testing. These simulations must show that the degree of deformation never exceeds a certain (undisclosed) value, thus ensuring no impact between the windings or permanent magnets can occur. Icona Nucleus will have an electric AWD drivetrain which is a 4 Elaphe L1500 in-wheel 110 kW motor in wheel producing 600 hp. “Combining those two aspects makes our measuring stations uniquely ‘universal’ in their ability to test motors of widely different types and characteristics, while complying with automotive standards.”. Prices are indicative only and may vary by country, with changes to the cost of raw materials and exchange rates. “In general, our testing strategy is based on three factors – testing based on OEM and international standards, then legislation, and lastly, internally identified tests based on design failure mode and effect analysis exercises, vehicle tests and simulations,” Lampic says. The Elaphe L1500 in-wheel motor is currently the brand's highest-performance product, producing 1500 Nm peak torque which available to each wheel throughout the speed range, delivering 110kW of maximum power to each wheel. “What we did – in our capacities as physicists – was to analyse the electromagnetic, thermal, mechanical and control aspects of the motor simultaneously, from the outset of the L1500’s development. Find out all of the information about the Elaphe Propulsion Technologies Ltd. product: electric vehicle wheel hub motor M700. The liquid-cooling circuit constitutes the active cooling of the L1500. Contact a supplier or the parent company directly to get a quote or to find out a price or your closest point of sale. LM will build those motors in its Ohio plant, alongside the trucks that will use them. First, the stiffness of the customer’s preferred bearing is characterised using Elaphe’s in-house numerical analysis software. Hairpin stators and similar configurations using discrete, short segments of copper conductor bars (rather than strands of wire, or ‘block coils’ cut from copper foil sheets) can be deformed as needed, to minimise overhangs and maximise the packing density in the stator slots without being damaged. They exclude delivery charges and customs duties and do not include additional charges for installation or activation options. This choice is driven by a range of reasons. ELA150S4D-1Y. THE concept N… “With more experience and our model accuracies optimised, we replaced the N40UH with N40SH, the latter being in the 150 C temperature class.”. The early results, which can be seen in the short video below, demonstrate that Elaphe’s L1500 in-wheel motor configuration can propel the electrified Audi R8 from 0 … The system is configured as a directdrive outrunner (meaning it has an external rotor and an internal stator). “Those standards have also informed our requirements for e-motor and inverter-specifi c performance parameters, EMC, electrical safety, durability and cable routing. Clean Energy Fuels Corp. has reached agreement with trucking firms to lease or purchase more than 250 new heavy-duty trucks, fueled by its Redeem RNG (renewable natural gas). “We knew from the outset that a lot of the technology we bought in for this vehicle will be obsolete by the time it … Elaphe integrates (from left to right) standard-issue tyres with 19 in rims, the L1500 housing (and rotor), its stator, standard automotive brakes and a standard bearing, to mount to the vehicle knuckle. Direct-drive synchronous AC motor: Liquid cooled, compact, high-torque (1500 Nm) for electric vehicles. “An OEM in collaboration with Elaphe can select their preferred bearing that fits within these parameters – and most existing OEMs and suppliers produce bearings that are suitable.”. AISIN Group Launching a $50 Million Automotive Fund Focused on Silicon Valley Technology. Lampic adds, “We invest resources in defi ning the brake, bearing, suspension, control and other requirements, building simulation models and characterisation procedures to determine whether a COTS or custom bearing can be used. The Elaphe™ L1500 in-wheel motor achieves the highest torque densities of electric motors on the market, generating 1500 Nm of torque without using any gears. The conductor bands can have a round or square cross-section, as well as a tangential shape to ‘u-bend’ around each stator tooth to the next, with at least one continuous band per phase of the motor (unlike the many separate bands used in hairpin stators). Automotive manufacturer Hyundai has a new incentive to lure buyers to its offerings with the 2016 Hyundai Elantra and the new Value Edition. In addition to being able to customise the in-wheel electric motor for carmakers’ preferred brake and bearing suppliers, the L1500’s performance and components can also be tailored to meet manufacturers’ application-specific requirements. Random vibration endurance is also tested, by combining a shaker table and a thermal chamber to apply vibrations at up to 2000 Hz and 40 g in force in the horizontal, vertical and axial directions. A thermal camera also records complementary data, and laser sensors measure axial and radial deformations of the rotor. “So while it’s a little harder for some of the wire to transfer heat to the liquid circuit, the net effect is that you end up with a cooler stator during operations. There is no tightening or straining of them, as might happen with copper strands, or any post-deformation as with hairpin stator conductors. Furthermore, wrapping wire in this way creates significant overhangs of copper, with strands sticking out from stator teeth (owing to the high number of turns around them) or protruding as they cross from one tooth to the next. I love the amp, and am glad I purchased it. Epson sure isn’t the first player with high powered laser projectors. In addition to having produced various motor mechanical layouts, Elaphe has also developed, tested and integrated its own motor inverters. The L1500 has been designed to enable it to be used in a wide range of OEM EVs and HEVs. 10-mag-2019 - Electric cars are not really a thing for petrolheads, but the torquey Elaphe L1500 In-Wheel motor could change that by the end of this year. These consist of 18 shocks, each measuring 100 g (in force) as well as 60 more shocks of 50 g each. The cost for Elaprase intravenous solution (2 mg/mL) is around $3,283 for a supply of 3 milliliters, depending on the pharmacy you visit. 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