Electric Vehicle Entrepreneurs

Thursday 9th March 2012

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

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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

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Radial Flux Laboratories – Development History

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Full encapsulation ofpermanent magnet

85% volume reduction10% higher power

Manufacturingcomplexity but

principle successful

14 Years Research andDevelopmentof concepts toproven product

The RFL Dual Stator concept met manufacturability objectives and has been developed to apply to a wide range of motor and generator product applications

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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 motor/ 16kW generator

177 kgs

Radial Flux Labs 16kW generator

17 kgs

Standard Industry manufacturing techniques

VIEW IN CROSS-SECTION

Design Process - Electrical FEA –Maxwell and ANSYSThis 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.

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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

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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.

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Design Process - Manufacturing Efficiency Stators

• Stator Laminations are designed to “nest” to facilitate use of centre material normally scrapped in conventional designs

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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

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Traditional Permanent Magnet Design compared to RFL Dual Stator

Rotor

Single stator

Ginlong

Dual statorRFL

PERM-MOTOR PMS 156

DC Brush ( Leroy Somer LSK2504CL

260 Rpm)

AC induction (WEG 8 Pole KTE168 740

Rpm)

PMG Inside Rotor (Ginlong 20 Kw

180 Rpm )

PMG Outside Rotor (CSIRO 20 Kw Westwind 211

Rpm)

RFL (211 Rpm )

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Kg/Nm

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PERM-MOTOR PMS 156

DC Brush ( Leroy Somer LSK2504CL

260 Rpm)

AC induction (WEG 8 Pole KTE168 740

Rpm)

PMG Inside Rotor (Ginlong 20 Kw 180

Rpm )

PMG Outside Rotor (CSIRO 20 Kw

Westwind 211 Rpm)

RFL (211 Rpm )$0.0

$5.0

$10.0

$15.0

$20.0

$25.0

Cost/NmEnergy Density

Due to it’s high output and compact design RFL motors/generators are:

• 90% cheaper per nm than current DC brushed motors

• 45% cheaper per nm than current AC induction

motors

• Up to 87% lighter for the same amount of torque

• Have up to 2.5x the energy density

• Over 90% efficiency at 90% of operating speed range

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 Power

21 Kw @ 1200 Rpm 29 Kw @ 3000 Rpm

Stator resistance & Poles

0.155 Ohms 8 Poles 16 Magnets

0.095 Ohms 18 Poles 18 Magnets

Stator Length 83.56 mm 50 mm

Stator OD 270.0 mm 230 mm

Active Material weight

79.5 Lbs( 36 Kg) 22.49 Lbs (10.2 Kg)

Cooling Liquid Liquid

Toyota Prius Gen ll vs RFL Dual Stator

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).

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.

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 materialsRFL 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

OVERLOAD COMPARISON PRIUS VS RFLThe 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

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 passengers3. High Energy Density enables a smaller and lighter wheel hub motor design influencing weight and bike styling4. 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

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.

RELUCTANCE TORQUE AND FIELD WEAKENING

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Efficiency against Output Power

RFL Eff

Kelly Eff

Field weekning RFL

Output Power

Effi

cie

ncy

FIELD WEAKENING

Field weakening is a motor control technique that allows a motor to run faster than its rated speed

Torque for Surface mount PM Motor using Field Weakening Control

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Field Weakening Region Constant Power for Surface Magnet Rotor

Rated Speed

FIELD WEAKENING

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Torque for Embedded Magnet PM Motor using Field Weakening Control

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Speed

Torq

ue Constant Torque region

Field Weakening Region Constant Torque for Embedded Magnet Rotor

Rated Speed

Phase advance region

100

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The RFL Business Plan

We offer manufacturers a compelling proposition: use our designs to dramatically reduce costs ,improve efficiency and performance