BLDC 5 HP, 48V MOTOR DESIGN FOR ELECTRIC MOBILITY WITH APPLICATIONS IN BOATS

Description

1 / 4 BLDC 5 HP, 48V MOTOR DESIGN FOR ELECTRIC MOBILITY WITH APPLICATIONS IN BOATS Field of invention

[001] Amazon, Natural Resources, Energy Transition, Sustainable Technologies, Electrical Engineering, Sustainable Engineering, Renewable Energies, Electric Mobility, New Materials, Mechanical Engineering. Fundamentals of the invention

[002] The intensification of the greenhouse effect brings serious climate changes to ecosystems and communities. To mitigate these effects, decarbonization is a necessary process for reducing or eliminating emissions of carbon dioxide (CO2) and other gases harmful to the environment. One of the main sectors that emits carbon dioxide is transportation, whether land, air, or water. Therefore, decarbonization of transportation becomes crucial, since the energy sources used in combustion engines are mostly of fossil origin.

[003] In this context, electric motors are a promising alternative for reducing environmental pollution, whether of the atmosphere, bodies of water and / or soil, are more efficient than combustion engines and can have electrical energy storage systems rechargeable by renewable sources such as wind and solar.

[004] Among the available technologies, Brushless Direct Current (BLDC) motors are brushless direct current motors that use converters / inverters for their drive and control. BLDC motor technology is quite widespread in the electric mobility sector, mainly due to its ease of speed control combined with its high volumetric energy density compared to other machine topologies on the market.

[005] In the developed machine, the determination of the materials for the composition of the electric motor occurred in such a way that the materials were evaluated through computer simulation. Thus, based on the efficiency of the system, the choice Petition 870250014938, dated 24 / 02 / 2025, page 6 / 33 Two-quarters of the materials were selected. In this regard, the material chosen for the permanent magnet was Neodymium-Iron-Boron (NdFeB), and the material chosen for the machine's core was the high-silicon ferromagnetic material (FeSi) 10JNEX9000.

[006] This electric machine will be used to replace the combustion engines used in small boats typical of the Amazon region. In this context, the local infrastructure is limited for road transport; thus, water transport is the main form of transport for people and cargo. The distances between towns and villages are large, making it necessary for the engines used to have higher energy efficiency than those available on the market. Brief description of the drawings

[007] Figure 1 shows a 3D view of the implemented equipment, where the engine parts can be observed as a whole.

[008] Figure 2 represents the geometric design of the machine in a side view, in which it is possible to visualize the dimensions relating to the length of the stator as well as the diameter of the shaft present in the motor rotor.

[009] Figure 3 shows the front view of the motor with information regarding the dimensions of the external and internal diameters of the stator and rotor.

[010] Figure 4 shows the magnetic flux density B (tesla), obtained through computer simulations, this parameter being fundamental for determining the efficiency in operating conditions of an electric machine.

[011] Figure 5 shows the magnetic potential vector, found through computer simulations, in which these parameters are essential for validation and machine performance.

[012] Figure 6 shows the BH curve of the 10JNEX900 material disposed in the core of the developed machine. Petition 870250014938, dated 24 / 02 / 2025, page 7 / 33 3 / 4

[013] Figure 7 shows the voltage delivered to the machine terminals in each of the three phases as a function of time during the simulations performed on the equipment.

[014] Figure 8 shows the behavior of the operating current profile of this motor as a function of time, starting from rest, based on the simulation developed.

[015] Figure 9 shows the behavior of the starting torque over time in milliseconds. Description of the invention

[016] This invention patent describes the design of an electric motor with BLDC technology with a power equivalent to 5hp and an effective supply voltage at the machine terminals in the range of 35 and 36 Volts and a current at the coil terminals of approximately up to 40 A, 36 slots, 6 pairs of magnetic poles, with a three-phase power supply system. The winding layout used in the machine was the double-layer diamond model with a coil pitch equal to 2, with 6 parallel paths and star connection of the coils. In addition, the slot area corresponds to approximately 108.8 mm2, in which 264 conductors were arranged per slot, with a gauge of 24 AWG, with 44 turns per phase.

[017] The materials used in the development of the project were the ferromagnetic material 10JNX900 implemented in the stator and rotor of the machine. The magnets used in the poles present in the rotor are made of neodymium N42UH and for the windings, copper was chosen for the implementation of the motor in question.

[018] With regard to the geometry of the machine under study, the stator's inner diameter is 95 mm, the outer diameter is 168 mm, the air gap has a height of 0.75 mm between the stator and the rotor. The rotor diameter is 94.25 mm, the magnet height is 3 mm, and the length of the motor corresponding to the stator is 54 mm with a total mass of 8.37 kg. Examples of how the invention can be implemented Petition 870250014938, dated 24 / 02 / 2025, page 8 / 33 4 / 4

[019] The electric motor with BLDC technology was developed and simulated using computer software, through studies related to rotating electrical machines and fundamental concepts of electromagnetism applied to low frequencies. The proposed model has its own characteristics with efficiency above 95% and the use of rare earth materials in its composition.

[020] The electric machine mentioned in this descriptive report can be realized through the manufacture of the motor by companies established in the Brazilian market that manufacture synchronous electric motors. Thus, the simulated model presents characteristics very close to commercially manufactured products, which are recognized by the scientific literature. Petition 870250014938, dated 24 / 02 / 2025, page 9 / 33

Claims

1 / 1 CLAIMS 1 DESIGN OF A 5HP, 48V BLDC MOTOR FOR ELECTRIC MOBILITY WITH APPLICATIONS IN BOATS, characterized by computer simulation, modeling and geometry of a Brushless Direct Current (BLDC) electric motor developed to replace internal combustion engines in small boats typical of the Amazon region. The designed electric machine has a power of 5 hp, with a DC supply voltage on the controller bus of 48 Volts and an effective voltage of 35 Volts rms (Root Mean Square) at the machine terminals, a nominal rotation of 3600 rpm, a mechanical torque on the shaft of approximately 9.75 Nm, 36 slots, 6 poles, 3 phases, 264 conductors per slot, 6 parallel paths, a diamond-shaped winding layout with a double layer with a coil pitch equal to 2 and 6 parallel paths, and a conductor gauge of 24 AWG. Composed of annealed copper, 10JNEX900 high silicon steel, N42-UH neodymium magnets, and an approximate efficiency of 94.84%.

2. PROJECT, according to claim 1, characterized by electromagnetic computer simulation with information relevant to motor performance.

3. PROJECT, according to claim 1, characterized by modeling in order to obtain a pilot project for computational simulations using the Finite Element Method.

4. PROJECT, according to claim 1, characterized by technical drawing in order to obtain the geometry with dimensions for modeling the electric machine except for the external casing.

5. ELECTRIC MOTOR, according to claim 1, characterized by containing rare earth materials for the permanent magnets (neodymium-iron-boron (NdFeB)), copper (Cu), annealed copper and M235-35a steel; furthermore, the machine core is composed of a high-silicon (Si) content steel. Petition 870250014938, dated 24 / 02 / 2025, page 10 / 33

Images