EMRAX 188 User Manual
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EMRAX 188 User Manual

Advanced axial flux synchronous motors and generators
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User's Manual for Advanced Axial Flux
Synchronous Motors and Generators
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  • Page 1 User’s Manual for Advanced Axial Flux Synchronous Motors and Generators www.emrax.com...

  • Page 2: Table Of Contents

    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.
  • Page 3 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 .................................
  • Page 4 User’s Manual for Advanced Axial Flux Synchronous Motors and Generators 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 www.emrax.com Version 4.5 / January 2017...
  • Page 5 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).

  • Page 6: Figure 1: Emrax Testing At Letrika D.d. Company

    User’s Manual for Advanced Axial Flux Synchronous Motors and Generators 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.

  • Page 7: 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.

  • Page 8: Figure 5: Emrax 208 Drawing

    User’s Manual for Advanced Axial Flux Synchronous Motors and Generators 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) www.emrax.com...

  • Page 9: Figure 7: Emrax 228 Drawing

    - 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) www.emrax.com Version 4.5 / January 2017...

  • Page 10: Figure 9: Emrax 268 Drawing

    User’s Manual for Advanced Axial Flux Synchronous Motors and Generators 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). www.emrax.com Version 4.5 / January 2017...

  • Page 11: Figure 12: Emrax 348 Drawing

    User’s Manual for Advanced Axial Flux Synchronous Motors and Generators EMRAX 348: Prototype is being tested. 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)

  • Page 12: Emrax 188 Technical Data Table

    User’s Manual for Advanced Axial Flux Synchronous Motors and Generators EMRAX 188 Technical Data Table Type EMRAX 188 EMRAX 188 EMRAX 188 High Voltage Medium Voltage Low Voltage Technical data Air cooled = AC Liquid cooled = LC Combined cooled = Air + Liquid cooled = CC...

  • Page 13: Emrax 208 Technical Data Table (Dynamometer Test Data)

    User’s Manual for Advanced Axial Flux Synchronous Motors and Generators EMRAX 208 Technical Data Table (dynamometer test data) Type EMRAX 208 EMRAX 208 EMRAX 208 High Voltage Medium Voltage Low Voltage Technical data Air cooled = AC Liquid cooled = LC...
  • Page 14 Graphs of the EMRAX 208 Medium and Low voltage motor type: Graphs of EMRAX 208 Low Voltage and EMRAX 208 Medium Voltage are similar to graphs of EMRAX 208 High Voltage. The only differences are the DC voltage and motor current. These two parameters can be read from the Technical data table for the EMRAX 208 Low and Medium Voltage motor.

  • Page 15: Emrax 228 Technical Data Table (Dynamometer Test Data)

    User’s Manual for Advanced Axial Flux Synchronous Motors and Generators EMRAX 228 Technical Data Table (dynamometer test data) Type EMRAX 228 EMRAX 228 EMRAX 228 High Voltage Medium Voltage Low Voltage Technical data Air cooled = AC Liquid cooled = LC...
  • Page 16 DC voltage and motor current. These two parameters can be read from the Technical data table for the EMRAX 228 Low and Medium Voltage motor. Low Voltage motor needs 4 x higher current and 4 x lower DC voltage for the same power/torque and RPM, compared to EMRAX 228 High Voltage motor.

  • Page 17: Emrax 268 Technical Data Table (Dynamometer Test Data)

    User’s Manual for Advanced Axial Flux Synchronous Motors and Generators EMRAX 268 Technical Data Table (dynamometer test data) Type EMRAX 268 EMRAX 268 EMRAX 268 Low Voltage or Technical High Voltage Medium Voltage EMRAX 268 Low Voltage** data Air cooled = AC...
  • Page 18 *EMRAX 268 VHML Low Voltage version always has 2 sequences of phase connectors (2x UVW). **Controller for EMRAX 268 Low Voltage motor should have very high peak and continuous motor current (1000 Arms peak and 500 Arms continuous). It is difficult to find such a high current controller in the global market.
  • Page 19 User’s Manual for Advanced Axial Flux Synchronous Motors and Generators www.emrax.com Version 4.5 / January 2017...
  • Page 20 Graphs of the EMRAX 268 Medium and Low voltage motor type: Graphs of EMRAX 268 Low Voltage and EMRAX 268 Medium Voltage are similar to graphs of EMRAX 268 High Voltage. The only differences are in the DC voltage and motor current. These two parameters can be read from the Technical Data Table for the EMRAX 268 Low and Medium Voltage motor.

  • Page 21: Emrax 348 Technical Data Table

    6009:6009 (for radial forces) for axial-radial forces contact EMRAX Company *Controller for EMRAX 348 Low Voltage should have very high peak and continuous motor current (1100 Arms peak and 550 Arms continuous). It is difficult to find such a high current controller in the global market. The most suitable would be the emDrive 500 from the Emsiso Company, which has 500 Arms continuous www.emrax.com...

  • Page 22: Intended Usage Of The Emrax Motor/Generator

    3. Motor types and additional motor parts The EMRAX motor family consists of 5 different motor sizes: 188 mm, 208 mm, 228 mm, 268 mm and 348 mm diameter. Each motor size can be air, combined or liquid cooled and each of them can also be made for high, medium or low voltage.
  • Page 23 Bearings for - Bearings are for radial forces. EMRAX 348 - These bearings are included serially (standard option). For axial-radial bearings contact EMRAX company Customized Special bearings - for e.g. in-wheel application. More information about bearings bearings at Item 16.
  • Page 24 Flanged Shaft with Inner splines (FSI) - It is mounted on the front motor side. Extended Shaft with Outer splines (ESO) and Flanged Shaft with Inner splines (FSI) - For EMRAX TWIN. - For power/torque transmission from front and back motor side. www.emrax.com...

  • Page 25: Order Codes, Tariff (Hts) Codes, Weights Of Emrax Motors And Additional Motor Parts

    *For more information about suitable sensors, for each controller, contact the controller producer. EMRAX bracket X shape for EMRAX TWIN X shape for one EMRAX motor 4. Order codes, tariff (HTS) codes, weights of EMRAX motors and additional motor parts Sample of order code: EMRAX_228_HV_LC(IP65)_ R _LTN_180 Tariff (HTS) Item code:...
  • Page 26 Tandem resolver LTN RE-15-1-A15 (e.g. for two Unitek Bamocar D3 controllers) with bracket mounted on TLTN the back side of the motor. For EMRAX TWIN (mounted on back side of the second motor) and when using two controllers with one motor (in this case two sequences of phase connectors are needed; 2xUVW).

  • Page 27: D Drawings Of Emrax Motors

    6. Mounting the motor Only use the drive if properly mounted on threaded bores intended for in the stator. Take a look at EMRAX drawings, where you can see mounting holes for each EMRAX model. EMRAX has an external rotor, which must not under any condition, not even for testing, be connected to the frequency converter or the power source, if the motor is not fixed in the manner described above.

  • Page 28: Power/Torque Transmission And Shafts

    User’s Manual for Advanced Axial Flux Synchronous Motors and Generators Brackets for mounting EMRAX motors are X shape brackets or they can be custom made. The X shape bracket is available for any motor size. It is made from stainless steel. Two X shape brackets can be connected together and used for mounting the EMRAX TWIN.

  • Page 29: Figure 17: Emrax Transmission Shafts

    EMRAX Company. If custom made shafts are needed, the customer can be provided with them – in this case the extended motor shaft from back motor side must be send to the EMRAX Company before the motor assembly (this shaft has to be made precisely for our motors according to drawings that are sent to the customer).

  • Page 30: Figure 18: Standard Motor Shaft Vs. Extended Shaft With Outer Splines (Eso)

    User’s Manual for Advanced Axial Flux Synchronous Motors and Generators Figure 18: Standard motor shaft vs. extended shaft with outer splines (ESO) Figure 19: ESO and FSI Figure 20: Standard motor shaft vs. EMRAX 268 VHML shaft Figure 21: FSI www.emrax.com...

  • Page 31: Figure 22: Emrax With Eso And Fsi

    User’s Manual for Advanced Axial Flux Synchronous Motors and Generators Figure 22: EMRAX with ESO and FSI Figure 23: Power/torque transmission from front motor side www.emrax.com Version 4.5 / January 2017...

  • Page 32: Figure 24: Power/Torque Transmission From Front (Fsi) And/Or Back Motor Side (Eso)

    User’s Manual for Advanced Axial Flux Synchronous Motors and Generators Figure 24: Power/torque transmission from front (FSI) and/or back motor side (ESO) Figure 25: Power/torque transmission from front motor side to the transmission gear www.emrax.com Version 4.5 / January 2017...

  • Page 33: Controlling Direction, Position And Rotation Speed Of Emrax Motors

    If custom made shafts are needed, customer can provide a shaft, which must be made precisely according to EMRAX drawings. The customer can provide a motor shaft or an extended motor shaft. The shaft dimensions must be discussed with the EMRAX Company before sending the shaft and mounting it in the motor during assembly.

  • Page 34: Figure 27: Resolver / Encoder On Back Motor Side

    User’s Manual for Advanced Axial Flux Synchronous Motors and Generators Figure 27: Resolver / encoder on back motor side www.emrax.com Version 4.5 / January 2017...

  • Page 35: Figure 28: Resolver / Encoder On Front Motor Side

    User’s Manual for Advanced Axial Flux Synchronous Motors and Generators Figure 28: Resolver / encoder on front motor side Figure 29: Encoder with bracket Figure 30: Resolver with bracket Hall sensors type: SS411P Power supply wires: www.emrax.com Version 4.5 / January 2017...

  • Page 36: Figure 31: Emrax With Hall Sensors

    WHITE GRAY GREEN Figure 31: EMRAX with hall sensors b) Drive control without sensor (sensor-less): - Direction of motor rotation (clockwise/counter clockwise) can also be defined without a sensor, if the controller has a sensor- less option. It can be defined by pole reversal, which can be achieved by a change of two motor phase cables. Three phase power connectors UVW are shown below in this Item.

  • Page 37: Figure 32: Motor Phase Connectors - Normal (Uvw) And Doubled (2Xuvw)

    User’s Manual for Advanced Axial Flux Synchronous Motors and Generators Figure 32: Motor phase connectors – normal (UVW) and doubled (2xUVW) www.emrax.com Version 4.5 / January 2017...

  • Page 38: Suitable Controllers For Emrax Motors

    The controller has to be selected according to the Technical Data Table of each motor (high motor current and voltage is very important). For some EMRAX motor types it is difficult to find a suitable controller even in the global market. It is especially difficult to find a controller with enough high current, which enables low voltage motors performances listed in the Technical Ddata Tables.
  • Page 39 For more information about suitable sensors, consult with the controller producer. Every sensor has to be mounted on the motor by a special bracket. If the resolver / encoder is bought from the EMRAX Company it is already precisely mounted on the motor by a special bracket when the customer receives the motor. Hall sensors are mounted in the motor during the motor assembly.

  • Page 40: Two Same Sized Emrax Motors Connected Serially (Emrax Twin) - Stacking Capability Of Emrax Motors

    10. Two same sized EMRAX motors connected serially (EMRAX TWIN) – stacking capability of EMRAX motors Two same sized EMRAX motors can be connected serially – this is EMRAX TWIN. All EMRAX motor types can be connected into TWIN. Figure 33: EMRAX TWIN drawing www.emrax.com...

  • Page 41: Figure 34: Emrax Twin With Encoder

    User’s Manual for Advanced Axial Flux Synchronous Motors and Generators Figure 34: EMRAX TWIN with encoder Figure 35: EMRAX TWIN with tandem resolver Figure 36: Coolant fittings for EMRAX TWIN Parts for EMRAX TWIN: - First motor needs the Extended shaft with outer splines (ESO)

  • Page 42: Redundancy

    EMRAX Company, otherwise the warranty does not apply. Figure 37: EMRAX TWIN shafts – ESO is mounted in the first motor and FSI on the front side of the second motor Figure 38: Motor with extended shaft and flanged shaft on the extended shaft (for EMRAX TWIN) 11.

  • Page 43: Emrax Motor Working As A Generator And Its Integration Into The Hybrid System

    (230V/50Hz) is needed. The EMRAX motor can be used in a hybrid propulsion system as a generator, which generates energy and charge the batteries in regeneration mode by using the controller and battery management system (BMS). The controller and BMS at the same time drive the diesel engine on the right power/RPM for charging the batteries at optimal level.

  • Page 44: Motor Cooling

    KTY 81-210. Other types can be mounted (e.g. PT1000) if the customer consults with the EMRAX Company in advance. EMRAX motors can be air cooled (IP21), liquid cooled (IP65) or combined cooled (IP21).

  • Page 45: Figure 42: Motor Coolant Fittings For One Motor

    Inlet water/glycol temperature and ambient temperature can also be lower – in this case the continuous motor power is higher. This is valid for all EMRAX motor sizes. To achieve a good inlet water/glycol flow rate which is recommended (from 6 to 8 l/min) the inlet pressure for...

  • Page 46: Emrax Motor Materials, Quality And Reliability

    15. EMRAX motor materials, quality and reliability EMRAX motors are quality made and consist of quality advanced materials. Materials are able to withstand extremely high power / torque (high temperature resistant, shatterproof, stiff) and are corrosion resistant.

  • Page 47: Emrax Motor Bearings And Life Expectancy

    8000 RPM (EMRAX 188 and 208 types). The generator voltage of EMRAX may vary for 1-2% at the same rotation speed. This is due to the difference of the magnetic field of the magnets (tolerance 1-2%). The difference in voltage also depends on the other materials of the motor.
  • Page 48 Life expectancy of the EMRAX motor is the same as life expectancy of the bearings that are mounted in the motor. If the bearings are overloaded than the bearing life time is shorter. They can be replaced.

  • Page 49: Emrax Motors As In-Wheel Motors

    EMRAX motor for in-wheel application must be totally closed (IP65; Liquid cooled). For most in-wheel applications EMRAX 268 VHML is appropriate. In every case forces that will be applied to the shaft and bearings should be discussed before placing an order.

  • Page 50: Starting Emrax Motor (Connecting The Motor With Controller)

     In case of damage, ship the drive back to the EMRAX Company for repairs. It is important, that you contact the EMRAX Company before sending the motor back.
  • Page 51 Figure 47: Isolation of electrical phase connectors with shrink hose  Mixing up the polarity of the battery or a short circuit leads to a destruction of the drive and means an acute fire hazard and danger of life! www.emrax.com Version 4.5 / January 2017...

  • Page 52: How To Choose The Correct Emrax Motor Type For Every Application

    RPM and torque (without transmission gear) do not exceed maximal RPM and torque listed in the Technical Data Table for the specific EMRAX motor. You also need to make sure, to consider the Torque/RPM graph! The torque also depends on the controller current of the motor, therefore the controller needs to have enough high phase current to get enough high torque.

  • Page 53: Usage Of Emrax Motors For Electric Vehicles (Ev)

    100 kW. But we recommended that you increase the battery voltage to get higher RPM and consequently higher power. 21. Usage of EMRAX motors for electric vehicles (EV) How to calculate power and torque for EV? 1. First you have to calculate the torque that will be needed for the vehicle (torque on the wheels):...

  • Page 54: Mounting Options Of Emrax Motor For Electric Car

    User’s Manual for Advanced Axial Flux Synchronous Motors and Generators For example, one EMRAX 228 motor can deliver 240 Nm peak torque and 120 Nm continuous torque. Therefore peak torque on the wheels in first gear is: ���������� �������� ������������ ���� ��ℎ�� ��ℎ�������� ���� ���������� �������� = 12 ∗ 240 ���� = 2880 ����...

  • Page 55: Example Of Calculation For Electric Audi Ett

    1900 Nm peak / 900 Nm continuous in the first gear. 2.) EMRAX 228 mounted in the TG is better option. You can expect much better EV acceleration, also you will be able to drive up the hill at higher gear: 3800 Nm peak / 1900 Nm continuous in the first gear .

  • Page 56: Emrax Certificates

    EMRAX motors. Every motor is tested before shipping at ambient conditions and parameters, which are described in the Technical Data Tables. If EMRAX motors are not used in accordance with this manual it causes a void of warranty. Products of the EMRAX Company have been developed for usage on electric vehicles, planes, boats, power plants.

  • Page 57: Service

    In case of a fault or damage, contact Company EMRAX: EMRAX d.o.o. Phone: +386 8 2053850 Pod hribom 4 E-mail: info@emrax.com 1235 Radomlje Web site: www.emrax.com Slovenia, Europe We now wish you lots of fun and success with your high performance EMRAX engine. www.emrax.com Version 4.5 / January 2017...

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