Sevcon Develops Motor and Controller

A new integrated motor and controller is being developed by microprocessor controls specialist Tech/Ops Sevcon‚ Inc. for use in industrial and on-road electric and hybrid vehicle applications. The new high performance Integra technology is designed for use in electric drives used for pumps and other auxiliary motor applications where the integrated design reduces wiring needs‚ takes up less engine compartment space and provides better system efficiency. The combined unit comprises a brushless permanent magnet AC (PMAC) motor‚ inverter and a universal shaft and integral fan. The variable speed drive allows programming of the system to provide a power save mode. The new Integra range will cover a range of battery operating voltages from 24 V to 80 V, with the initial version being for use in 36 V and 48 V systems. The product line will offer a wide power range staring with the initial offering at 12 kW (S3) and 4.2 kW (S1) at 48 V. The motor maximum speed is 4,500 rpm and minimum speed is 2,500 rpm.

By allowing generation and delivery of electrical power during the drive cycle‚ Integra can continue to operate pumps and compressors efficiently when the engine is not running. Integra has multiple applications from on-road and off-road electric vehicles‚ trucks and bikes to industrial vehicles such as fork lifts, utility and mining vehicles. In improving power consumption and efficiency, Integra reduces the mechanical load placed on the engine, particularly in the operation of the vehicle's ancillary systems such as heating and air conditioning. As a result, engine size can be reduced by OEMs. The sensoreless PMAC motor with an integrated inverter is designed to allow the replacement of separate electric components with one high efficiency compact system saving both space and weight. Integra reduces the mechanical load on internal combustion engines using energy stored in the electrical system to power ancillary systems, improve their efficiencies and reduce emissions. The combined unit is equipped with a fully integrated set of inputs and outputs designed to handle a range of vehicle requirements and are CANopen compliant for configuration and diagnostic purposes.