Lightweight design and prototyping of high performance permanent magnet synchronous machines for an electric driven racing car

Abstract

The paper discusses design, manufacturing and testing of a prototype permanent magnet synchronous machine for the application in an electric driven racing car. Very high performance and low mass of these machines are achieved by using a Halbach magnet array with a novel segmentation technology for reducing the eddy currents, high performance FeCo stator sheets as well as a fractional slot stator winding build of tooth coils. The final design of these 40 kW / 30 Nm machines yields a total mass of only 3.95 kg. The operating range is up to 18000 rpm with a nominal speed of 12600 rpm.