Sevcon introduces new integrated motor and controller for on-road applications
20 December 2010
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| Main assembly of the Integra integrated motor and controller. Click to enlarge. |
Microprocessor controls specialist Sevcon has developed a new integrated high performance motor and controller for use in industrial and on-road electric and hybrid vehicle applications. The new Integra technology is designed to provide traction and motor drive control. In EV battery and fuel cell applications Integra will provide traction power and in hybrid EVs the system can provide range extension capability and battery charging functionality.
The combined unit comprises a brushless permanent magnet AC motor‚ inverter and a universal shaft and integral fan. The variable speed drive allows programming of the system to provide a power save mode.
The new Integra product range is intended to cover a range of applications and battery operating voltages from 12V to 80V, the initial version being for use in 48V systems. Output power over the range will vary between 4 kW and 17 kW.
As well as improving the drive efficiency and the range of electric systems, in hybrids‚ Integra reduces the mechanical load on internal combustion engines using energy stored in the electrical system to power ancillary systems, improve their efficiencies and reduce emissions.
By allowing generation and delivery of electrical power during the drive cycle‚ Integra can continue to operate pumps and compressors efficiently when the engine is not running.
The sensorless PMAC motor with an integrated inverter is designed to allow the replacement of separate electric drivetrain components with one high efficiency compact system saving both space and weight.
Integra has multiple applications from on-road and off-road electric vehicles and bikes to industrial vehicles such as fork lifts, utility and mining vehicles, the company says.
he combination of motor and controller is not new but Integra offers huge performance advantages over existing technology. There’s a real market need for this. Over the last 12 months we have had enquiries from several large OEMs interested in the Integra concept. They want a small motor and controller to take the load off internal combustion engines and act as a generator during operation.
The integrated electronic system allows previously separate components to be replaced by a single, more compact application with space saving advantages. Integra’s compact nature gives it a high power to volume ratio ten times more powerful than current designs. It also achieves a level of efficiency over and above anything else commercially available.
—Matt Boyle, CEO
In improving power consumption and efficiency, Integra reduces the mechanical load placed on the engine, particularly in the operation of the vehicle’s ancillary systems such as heating and air conditioning. As a result, engine size can be reduced by OEMs.
Lots of PR on this one. It will not generate or store FREE energy for ancillaries. At most it may be a 95% to 97 % efficient generator or drive e-motor.
Posted by: HarveyD | 20 December 2010 at 12:33 PM
Price, weight, dimensions, etc would enhance the article.
Posted by: kelly | 20 December 2010 at 12:49 PM
On this one, price IS a big deal :)
Posted by: SJC | 20 December 2010 at 12:54 PM
I'd like to see siamesed with traction control integration in most all E-drive offerings as a goal.
@ Harvey, it's not clear that this unit can't do regen braking which is free!
O course many people have made the point that no rare earths are needed and there is no performance loss associated with loss of magnetism.Minimal efficiency loss is balanced by wider scope and versatility once the control device is provided.
Posted by: Arnold | 20 December 2010 at 08:54 PM
At 4kW to 17kW, this is only good for small vehicles like warehouse carts and flatbeds. Nowhere near enough power for even a small car.
Posted by: Eletruk | 21 December 2010 at 11:09 AM
Arnold. Most existing e-drives can do re-gen. Does this one do it that much better? The electrical side of electrified vehicles is already close to 95% efficient. Of course, another 1% to 2% is possible.
Improved, much lower cost, electrical/electronic parts such as e-motors/gen, controllers, chargers and ancillaries will be mass produced worldwide very soon.
Improved performance storage units are urgently required before EV mass production takes off.
Posted by: HarveyD | 21 December 2010 at 11:12 AM
The motor also "can provide range extension capability and battery charging functionality." In other words, it's a fully-capable motor-generator.
17 kW is more than the peak capacity of GM's new BAS system in the LaCrosse. It's also enough to drive many cars on level ground at 60 MPH. Creeping in traffic could easily be done in electric mode.
Posted by: Engineer-Poet | 22 December 2010 at 08:03 AM
This motor is intended for cooling pump, power steering, air compressor NOT for traction motor.
Posted by: wanderer | 03 January 2011 at 07:43 AM