2. What is the Radial Flux Laboratories business
• RFL designs high efficiency, low cost electric motor/generators and
electronic drives suited to a multitude of applications that are
- half the weight and cost of conventional motors or generators
- easily manufactured, in many cases by standard automated
winding machinery, requiring no special components or materials
- have efficiencies in the 90s% range
• RFL provides under license
-ready-to-manufacture designs
-supply complete product to order
• RFL typically licenses applications of the technology for specific
market applications
2
3. RFL has developed 2 technology platforms, each
capable of multiple end use applications
• Dual stator with rectangular permanent magnet rotor
which can be configured for
- wind turbine generator
- small inverter genset
- large inverter genset
- industrial electric motors
- electric vehicle and bike motor/generator
• Single stator design with flat permanent magnets
-inverter less small gensets
-large inverter less gensets
3
4. Radial Flux Laboratories – Development History
14 Years Research and
Development
of concepts to
proven product
Full encapsulation of 85% volume reduction
permanent magnet 10% higher power
Manufacturing
complexity but
principle successful
4
5. The RFL Dual Stator concept met manufacturability
objectives and has been developed to apply to a wide
range of motor and generator product applications
5
6. Radial Flux Labs has developed a unique, optimized stator-
rotor architecture
•New design of copper stator elements
•New permanent magnet configuration
•Patented Rotor Design
•Maximum magnetic flux - higher power, greater efficiency, less weight
Conventional 20kVA Radial Flux Labs 16kW
motor/ 16kW generator generator
177 kgs 17 kgs
Standard Industry
VIEW IN CROSS-SECTION
manufacturing
techniques
6
7. Design Process - Electrical FEA –Maxwell and ANSYS
This analysis optimised the concept design of the 20kw
generator to deliver high levels of flux density across the air
gap between the rotor and the stators, while maintaining
good levels of flux consistency.
7
8. Design Process - Mechanical FEA - Deformation
Analysis undertaken on the concept design to determine
thepossible levels of deformation displayed by the generator
due to the magnetic and mechanical forces
8
9. Design Process - Mechanical FEA – Heat
RFL’s design allows the dual stators to be mounted directly
on the casing plate facilitating a high level of heat transfer
from the stator to the casing.
9
10. Design Process - Manufacturing Efficiency
Stators
• Stator Laminations are designed to “nest” to facilitate use
of centre material normally scrapped in conventional
designs
10
11. Testing –Small Wind 20 kw Turbine
Testing was on a platform designed to the Garrad Hassan (UK)
specification as used for the independent testing of the 3 kw
micro wind generator
11
13. Cost/Nm
$25.0 Energy Density
$20.0
$15.0 Due to it’s high output
$10.0
and compact design RFL
motors/generators are:
$5.0
$0.0 • 90% cheaper per nm than
PERM-MOTOR PMS DC Brush ( Leroy AC induction (WEG 8 PMG Inside Rotor PMG Outside Rotor RFL (211 Rpm )
156 Somer LSK2504CL
260 Rpm)
Pole KTE168 740
Rpm)
(Ginlong 20 Kw 180
Rpm )
(CSIRO 20 Kw
Westwind 211 Rpm)
current DC brushed motors
Kg/Nm • 45% cheaper per nm than
current AC induction
0.90
motors
0.80
0.70
• Up to 87% lighter for the
0.60
same amount of torque
0.50
0.40 • Have up to 2.5x the energy
0.30 density
0.20
0.10 • Over 90% efficiency at 90%
0.00 of operating speed range
PERM-MOTOR DC Brush ( Leroy AC induction (WEG PMG Inside Rotor PMG Outside Rotor RFL (211 Rpm )
13 PMS 156 Somer LSK2504CL 8 Pole KTE168 740 (Ginlong 20 Kw 180 (CSIRO 20 Kw
260 Rpm) Rpm) Rpm ) Westwind 211
Rpm)
14. Toyota Prius Gen ll vs RFL Dual Stator
Toyota Prius Gen II RFL
Max Torque 339 Nm @ 250 Amps 340 Nm @ 250 Amps
Nominal Max Power 50 Kw @ 1200 Rpm 45 Kw @ 1500 Rpm
Tested continuous
21 Kw @ 1200 Rpm 29 Kw @ 3000 Rpm
Power
Stator resistance & 0.155 Ohms 8 Poles 16 0.095 Ohms 18 Poles 18
Poles Magnets Magnets
Stator Length 83.56 mm 50 mm
Stator OD 270.0 mm 230 mm
Active Material
79.5 Lbs( 36 Kg) 22.49 Lbs (10.2 Kg)
weight
Cooling Liquid Liquid
SOURCE
• US Department of Energy reports into the Prius motor undertaken by the Oak Ridge National Laboratory. (Report references:
ORNL/TM2004-185 , ORNL/TM-2004-247, ORNL/TM-2005/33, ORNL/TM-2004/137 ).
15. KEY DESIGN FEATURES OF RFL VS PRIUS
•The RFL base design is of a comparable torque and utilizes
less than a third of the active material that the Prius
•Scaling the RFL design to the same size as that used in the
Prius increases the power output to 104.5 Kw and a max
torque of 783 Nm compared to the Prius at 50kw and a max
torque of 339 Nm
•This is powerful enough powerful enough to free the Prius
from the real-time assistance of a combustion engine .
•This is possible due to its exceptional torque, high overload
start up and a lightweight and compact design.
16. ACTIVE MATERIAL COMPARISON PRIUS VS RFL
To achieve its rated levels of output the Prius design has
used significant amounts of copper and other active
materials
RFL design makes much more effective use of a smaller
amount of material resulting in a staggering reduction of
active materials of over 70%. as can be seen in following
photographs
17. OVERLOAD COMPARISON PRIUS VS RFL
The critical issue of starting torque at take off point is a
function of the overload capacity of the motor design. The
Waveform comparison below illustrates the exceptional
performance of the RFL design
Phase A-B
Phase A
18. OPTIMIZED MOTOR AND CONTROLLER
DESIGN FOR ELECTRIC VEHICLES
1. High Electrical Efficiency across the desired rev range
which determines the distance travelled on a given charge.
2. High starting torque ensures the start up acceleration
capability and hill start and climbing capability will give
useful real world performance with passengers
3. High Energy Density enables a smaller and lighter wheel
hub motor design influencing weight and bike styling
4. High Regeneration energy recovery for battery recharge
under braking deceleration provides the boost to battery life
for useful travel distance, particularly in daily city commuter
traffic
19. MOTOR DESIGN CHARACTERISTICS
• embedded permanent magnets have their magnetic
orientation tangential to the flux in the stator windings
•high saliency in the rotor
•high reluctance torque
•phase advance
•field weakening
•no demagnetization under high current loads
•lower running frequency from the lower pole number
giving lower stator core losses.
20. RELUCTANCE TORQUE AND FIELD WEAKENING
Efficiency against Output Power
1
0.9
0.8
0.7
0.6 RFL Eff
Efficiency
Kelly Eff
0.5
Field weekning RFL
0.4
0.3
0.2
0.1
0
0 1000 2000 3000 4000 5000 6000 7000 8000
Output Power
i
21. FIELD WEAKENING
Torque for Surface mount PM Motor using Field
Weakening Control
60
50 Rated Speed
40
Torque
30 Constant
Torque
20
region
10 Field Weakening Region Constant Power
for Surface Magnet Rotor
0
0 2000 4000 6000 8000 10000 12000
Speed
Field weakening is a motor control technique that allows a motor to run
faster than its rated speed
22. FIELD WEAKENING
Torque for Embedded Magnet PM Motor using Field
Weakening Control
100
Phase advance region
60
Rated Speed
50
40
Torque
30 Constant Field Weakening Region Constant
Torque Torque for Embedded Magnet Rotor
i 20
region
10
0
0 2000 4000 6000 8000 10000 12000
Speed
23. The RFL Business Plan
We offer manufacturers a compelling proposition: use our designs to
dramatically reduce costs ,improve efficiency and performance
23
