1.

MOTOR SELECTING PROCESS

Electric motor is used to rotate the wheel. There are 4 main types of electric motors that are
significant for EVs as well. They are

1. Brushed DC Motor

2. Induction Motor

3. Permanent Magnet Brushless DC Motor

4. Switched Reluctance Motor

Table 1Type of Motors

DC Motors Induction Motors PM Motors SR Motors

Power Density Low Intermediate High Very High

Peak Efficiency <90 90-95 95-97 <90

Load Efficiency 80-87 90-92 85-97 78-86

Hard for field

Controllability Simple Complex Complex
working

Reliability Normal Good Excellent Good

Heat Dissipation Bad Bad Good Good

Size & Weight Big/Heavy Normal/Normal Small/Light Small/Light

High-speed Performance Poor Excellent Good Excellent

Cost of Controller Low High High Normal

The brushed DC motor is one of the main types utilized across industries. However, according to
the data table, permanent magnet (PM) motors stand out as particularly advantageous for electric
vehicle (EV) applications. Once the motor type is chosen, attention must then shift to various other
factors that significantly influence performance. Those are

 Power Rating
 Torque
 Efficiency
 Weight
 Size and Integration
 Controller Compatibility
 Regulatory Compliance
 Maintenance Requirements
 Cost

In electric vehicles (EVs), the power rating of the motor directly impacts its ability to propel the
vehicle efficiently and achieve desired acceleration and speed. Higher power ratings generally
result in greater torque and acceleration capabilities, allowing the vehicle to perform optimally,
especially in demanding driving conditions such as uphill climbs or high-speed acceleration.

Figure 1 Full Motor Calculation

We are aiming to achieve a maximum speed of 60 km/h for the bike, taking into account a total
weight of approximately 171 kg, including the weight of the bike and the passenger.

o Vehicle weight = 70 kg
o Motor weight = 8 kg
o Battery weight = 3 kg
o Rider and accessories = 90 kg
o Total load = 171 kg

The vehicle parameters have been predetermined based on the selected bike, rendering other
specifications dependent on this initial configuration.

o Tire Width - 20 mm
o Width - 770 mm
o Height -1072 mm
o Ground Clearance - 170 mm

1. Power rating and torque

Based on the numbers you provided:

o Maximum power output: ~ 6 kW

o Torque applied on the motor: ~ 10 Newton-meters
o Required average power: ~ 3-4 kilowatts

Above figures give a clear idea of the power and torque demand of the vehicle. With a maximum
power output of around 6 kW, the motor should be able to deliver this level of power when needed,
perhaps during acceleration or on a steep hill.

The specified torque indicates the maximum rotational force required to drive the vehicle
approximately 10 Nm. This torque requirement affects the design and selection of the motor so
that it can provide enough torque for different riding conditions. Generally, the maximum torque
provided by the engine in a CT100 bike is around 8.24Nm. Thus the maximum torque through
the motor is 10. A typical power requirement of up to 3-4 kW suggests typical power demand in
typical driving situations such as cruising at a constant speed on flat terrain.
 2. Efficiency

Permanent Magnet Brushless Motors (PMBM), which are commonly used in electric vehicles
(EVs) for their high efficiency and performance. Here's a breakdown of the efficiency values you
provided:

o Peak Efficiency: 95-97%

o Load Efficiency: 85-97%

These efficiency figures indicate that PMBM technology offers excellent performance,
especially compared to other types of motors. The peak efficiency of 95-97% suggests that these
motors convert a high percentage of input power into mechanical output power, minimizing
energy loss. Additionally, the load efficiency range of 85-97% suggests that even under varying
load conditions, PMBM maintains relatively high efficiency levels.

When compared to other types of motors, such as brushed DC motors or induction motors,
PMBM typically outperforms them in terms of efficiency, compactness, and power-to-weight
ratio. This makes PMBM the preferred choice for electric vehicle propulsion systems where
maximizing efficiency and range are critical factors.

3. Weight

When replacing the engine of a motorcycle with a motor, it's important to consider the weight
distribution and balance of the bike. The weight of the motor should ideally be similar to that of
the original engine to maintain the bike's balance and handling characteristics. In the case of the
CT100 bike, if the original engine weight is around 30 kg, if I want need to choose a motor that is
approximately the same weight. This ensures that the overall weight distribution remains similar
to the original design, minimizing any adverse effects on handling and stability. Additionally,
factors such as mounting points and placement of the motor should also be taken into consideration
to ensure proper integration without compromising the structural integrity or performance of the
motorcycle.

The weight of a 48V, 3kW brushless permanent magnet motor can vary depending on its design,
materials used, and additional components. However, a rough estimate for such a motor might be
in the range of 10-15 kg. If we planning to replace the engine of a CT100 bike with this type of
motor, you'll want to ensure that the weight is within a reasonable range compared to the original
engine weight of around 30 kg, as you mentioned earlier. This will help maintain the balance and
handling characteristics of the bike.

4. Size and Integration

Motor dimensions is

o Length: 131 mm
o Width: 125 mm
o Height: 97 mm

Dimensions of the motor are significantly smaller than the dimensions of the currently used bike
engine, we need to create an external housing to accommodate the motor and its control system.
Here's an updated approach based on the provided values:

 Designing the External Housing:

Design a housing that provides sufficient space for the motor and control system while adhering
to the dimensions of the existing engine mount positions. The housing should be designed to fit
within the dimensions provided for the bike engine

o Length: 300-350 mm
o Width: 200-250 mm
o Height: 200-250 mm

 Mounting Positions:

Ensure that the mounting positions of the external housing align with the existing mount positions
on the bike frame to facilitate installation. Use appropriate brackets or mounting points to securely
attach the housing to the bike frame.
  Integration with the Bike Frame:

Ensure that the external housing integrates seamlessly with the bike frame to maintain the overall
aesthetics and structural integrity of the vehicle. Pay attention to clearance and spacing to avoid
interference with other bike components.

 Accessibility:

Design the housing with easy access points to allow for maintenance and servicing of the motor
and control system. Consider incorporating removable panels or access doors for convenient
access to internal components.

 Protection from Elements:

Implement measures to protect the motor and control system from environmental factors such as
moisture, dust, and debris. Use sealing materials or gaskets to ensure the housing provides
adequate protection against water and dust ingress.

 Safety Considerations:

Ensure that the housing design complies with safety standards and regulations applicable to electric
vehicle components. Take precautions to prevent accidental contact with live electrical
components within the housing.

Using these guidelines, we can create an external housing that effectively accommodates the
smaller motor and control system while maintaining compatibility with the existing bike frame
and mount positions.

5. Controller Compatibility

Here the full control done through the ESC unit.

6. Regulatory Compliance
 7. Maintenance Requirements

Maintenance requirements for Permanent Magnet Brushless DC (PMBDC) motors are relatively
low compared to traditional brushed motors due to their simplified design and lack of brushes.

 Keep the Motor Clean

 Monitor Operating Conditions
 Inspect Electrical Connections
 Check for Bearing Wear
 Monitor Performance
 Protect Against Overloads
 Environmental Considerations
 Follow Manufacturer Guidelines
 Professional Inspection and Servicing:

By following these maintenance practices, we can ensure the reliable operation and longevity of
Permanent Magnet Brushless DC motors in various applications. Regular maintenance helps
prevent unexpected failures and ensures consistent performance over the motor's lifespan.

8. Cost

The cost of a Permanent Magnet Brushless DC (PMBDC) motor can vary depending on several
factors such as the motor's power rating, size, efficiency, brand, and additional features.
Additionally, the cost may also be influenced by the quantity purchased and any customization
required for specific applications.

Based on the specified requirements and calculations, a Permanent Magnet Brushless (PMB)
motor emerges as the optimal choice for the intended application. The desired power output falls
within the range of 3-4 kW, with a maximum power requirement extending up to 5 kW for peak
performance. The operating voltage is expected to lie between 48-60 volts. Moreover the
maximum value provided by the engine in the bike is only 5500. In order to achieve the maximum
speed of 70 expected to be achieved here, the motor must achieve a maximum RPM value of 6000
near the gear.
Considering these factors, the most suitable motor type and corresponding specifications would
entail a Permanent Magnet Brushless Motor with a power rating between 3-5 kW and an operating
voltage range of 48-60 volts. Additionally, achieving the desired maximum speed may necessitate
an RPM capability reaching or exceeding 6000 RPM in proximity to the gear mechanism.
Therefore, considering these factors, the most suitable motor type and motor values are as follows.

Power: 3000W

Peak power: 5200W

Maximum speed: 4600 RPM

Rated torque: 10.3 Nm

Peak torque: 41 Nm

Rated current: <58A

Rated voltage: 60V

Rated efficiency :> 83%