PML Flightlink

In-Wheel Hi-Pa Drive Motors

Andrew Vallance
25/06/08

Hi-Pa Drive

www.pmlflightlink.com

PML History

1963 Company Established Pioneered Printed Armature Motors

1989 Developed powered wheelchair motors and controllers

2001 Focus on high performance motors and drives

2003 Development focuses on wheelmotor technology

2004 First multiwheel wheelmotor driven vehicle

2006 First public debut of the Hi-Pa Drive technology

2007 First Hi-Pa Drive equipped OEM vehicle shown to the public

PML printed armature motors

NEO Wheelchair controller

Praze, electric scooter. A development project with Peugeot using an in-wheel motor

A submarine winch-motor, built using wheelmotor technology

Solar challenge racing vehicles built buy universities in Turkey. Several teams used PMLs motors and drives, these teams achieved 2nd, 3rd, 4th and the fastest lap

A Hi-Pa Drive wheelmotor debuted at the 2006 British International Motor Show

Volvo ReCharge; a vehicle that uses 4 Hi-Pa Drive inwheel motors debuted at the 2007 Frankfurt Motor Show

Hi-Pa Drive

www.pmlflightlink.com

Hi-Pa Drive

Unique highly parallel design (Hi-Pa Drive)

Groundbreaking integrated power electronics for drive control and inverter Integrated cooling and braking system Fully-scaleable

Example peak motor performance (HPD40)

120kW motor 160hp 750Nm of torque 25kg

Hi-Pa Drive

www.pmlflightlink.com

Hi-Pa Drive

Enables the next evolutionary step in hybrid vehicle technology Permits radical re-design of vehicles Industry shift from hardware to software A commercially-viable and practical solution Plug and Play with existing automotive infrastructure for both manufacturing and distribution A cost reduction opportunity for OEMs Supports the progression to full electric vehicles as advances in battery technology are achieved

Hi-Pa Drive

www.pmlflightlink.com

OEM Application

Volvo ReCharge

Released at the 2007 Frankfurt Motor Show

Hi-Pa Drive

Uses 4 x Hi-Pa Drive in-wheel motors, 60kW Integrated starter generator, master controller, a lithium polymer battery pack and an in-car display 11 month development program Recently ordered 2nd test vehicle

www.pmlflightlink.com

OEM Application

Volvo ReCharge

Hi-Pa Drive

www.pmlflightlink.com

Hi-Pa Drive

400mm diameter 120mm deep 750Nm peak torque

Hi-Pa Drive Motor Peak power Motor weight Inverter drive weight Gear box weight Total weight
Hi-Pa Drive

3 Phase Induction Motor 120kW (160hp) 160kg 41kg 45kg 246kg

Volvo D5 Engine 120kW (160hp) 163kg Not required 40kg 203 Kg

120kW (160hp) 25kg Integrated within the HiPa Drive Motor Not required 25 Kg

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How the Hi-Pa Drive Attaches

Suspension carrier
A standard suspension carrier

Rotor Wheel
A standard wheel. All the road shocks and loads are carried through the wheel bearing to the suspension carrier rather than through the stator and rotor This component attaches to the wheel bearing, allowing it to rotate.

Stator
This mounts to the vehicles suspension carrier and does not rotate. The coils, power electronics and water cooling (not shown) are mounted onto this plate

Wheel bearing
This is the vehicles standard wheel bearing. The rear face of the wheel bearing is connected onto the stator and suspension carrier whilst the front face is connected to the rotor and wheel.
Hi-Pa Drive
www.pmlflightlink.com

New Technology?

1898 Ferdinand Porsche designs the first hub motor driven car Fleet of 300 electric delivery vehicles using in-wheel motors 1901 Lohmer-Porsche race car 4wd electric

Hybrid car with electric motors in the wheels, and Porsches 1901 race car of similar design

Hi-Pa Drive

www.pmlflightlink.com

Competitor Benchmarking

Direct drive inwheel motor Level of Integration

TM4
0.66 0.56 1 5.0

PMLs Hi-Pa Drive

Mitsubishi
1.3

E traction

Apex

Perm (AG)
1.11

Bluewav
1.02

UQM
1.1

Inboard mounted motor and gearbox

0.92

Zytek
1.14 Raser

0.6

LE Electronics

1.0
Hi-Pa Drive

2.0

3.0 4.0 5.0 Density (Maximum KW per KG)

6.0

7.0

8.0

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The Real State of The Art Today

Maximum power and torque density diagram for a variety of traction motors in EVs and HEVs.

N. Matsui, Progress for the last decade and perspectives in application specific electric motors and drives in Japan, Keynote speech, the 4th International Power Conversion Conference, Nagoya, Japan, 2-5 April 2007, pp.K17-K21.

Hi-Pa Drive

www.pmlflightlink.com

24

The Real State of The Art Today

The future of Hi-Pa Drive technology

PML HPD 40

30Nm/kg 120kW

Maximum power and torque density diagram for a variety of traction motors in EVs and HEVs.

N. Matsui, Progress for the last decade and perspectives in application specific electric motors and drives in Japan, Keynote speech, the 4th International Power Conversion Conference, Nagoya, Japan, 2-5 April 2007, pp.K17-K21.

Hi-Pa Drive

www.pmlflightlink.com

24

Research Priorities

Regenerative braking

Full and partial regenerative braking + methods of integration with mechanical brakes Regulatory approval Energy management

Platform vehicle architectures and technologies

Technology that can be easily scaled between models and manufacturers

Battery technology

Hi-Pa Drive

High charge and discharge rates Increased energy and power density Volume production to reduce costs
www.pmlflightlink.com

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Research Priorities

Partnerships
Greater cooperation between OEMs, suppliers and small specialist companies

Reducing OEM cost

Construction cost Assembly cost New vehicle introduction time/ cost

Higher torque density / higher power density Greater range of applications

Ehanced vehicle dynamics research

Capitalising on high torque benefit

Hi-Pa Drive

www.pmlflightlink.com

Hi-Pa Drive
No Compromise!

Hi-Pa Drive

www.pmlflightlink.com