In the world's top electric glider competition
Pushing the limits of miniaturization, high power, and high efficiency motors
With global warming and the depletion of crude oil, the current automotive industry is facing tremendous changes, the development trend of electrified vehicles will continue to accelerate, and the importance of on-board motors and related technologies will be raised to a new height. For automotive motors with complex load changes and limited placement space, it is necessary to meet the technical requirements of miniaturization/high power, wide range of variable speed operation, low noise, and adaptation to a wide range of temperature changes.
For Japan Electric, automotive motors, especially automotive drive motors, will be the next extremely important industrial area for growth. In order to effectively master and accumulate technology and experience in on-board drive motors and related fields, Japan Denco Corporation has taken participation in the F5B electric glider competition as a practical object. The F5B is known as the F-1 among remote-piloted aircraft, and it is indispensable to quickly accelerate the entire aircraft to a flight speed of 200 km/h (vertical ascent speed), with a large output and a compact and lightweight motor. In addition, in order to achieve excellent results in the world championship and win the world championship, it is necessary to develop a high-performance motor for the model aircraft, as well as a system that includes ECUs, batteries, and data loggers, as well as comprehensive capabilities that can be used in practical applications.
The F5B motor developed by Japan Electric Corporation has met the technical requirements of an input voltage of 19.5V (average), a maximum current of 300A, and a maximum output of 2.4kW/84,000rpm. In terms of rotational speed, the speed of the F5B motor has greatly exceeded the 20,000 rpm speed of the fan motor for the server, which is called high speed, and even during the development process, the centrifugal force generated by the high speed caused the magnet to fly away. The F5B motor, which has dimensions of only φ39 mm × 110 mm and weighs only 300 g, has a power-to-weight ratio of 8 kW/kg, far exceeding the power-to-weight ratio of the F-1 engine by 6 kW/kg. In addition, in view of the low voltage/high current drive method used in these motors, which leads to problems such as an increase in the internal temperature of the motor and an increase in the magnetic field, we decided to replace the semiconductor sensor with a sensorless control system. Finally, the limited processing power of the small package microcomputer due to the limitation of installation space forced us to adopt a more compact method to install the data calculation software. To sum up, in the development process of the F5B motor, we have overcome various technical problems in all aspects such as hardware and software.
The F5B motor, which has an external dimensions of only 39 mm × 110 mm and a weight of only 300 g, has a maximum output of 2.4 kW. Through continuous efforts, we were able to solve the problem of heat generation caused by centrifugal force and high current, and won the world's No. 1 crown. Since the project was launched in 2005, the first prototype was developed in 2006, the first Japan Championship was won in 2007, and the World Championship was ranked in 2010. The F5B motor, which has won the world's No. 1 position, has low voltage, high current, miniaturization, battery drive and other performance characteristics that fully meet the technical requirements of automotive motors. In addition, the ECU developed in parallel with the motor is suitable for use as an automotive component due to sensorless control that meets the requirements for use in high-temperature environments and wire saving, as well as its excellent performance in speed control.
Motor technology is indispensable for the realization of gas-free EVs. Japan Denco (Nidec) is also conducting research and development on various aspects of EVs based on the experience gained through the F5B.
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