Motor for Electric Karting league

Status
Not open for further replies.

redline2097

New member
Messages
5
Reaction score
0
Hi!

We are starting 20 cars electric karting league to ages 10-14 old. We are seeking for suitable motors. Our highest bet at the moment is HPM5000B golden motor. Is there any better choices under $600 piece?

We need it to be capable of:
-74v (84v hot off the charger)
-7kw continuos power
-15kw peaks

Weight is not the issue. Looking for best quality product to meet the specs.
 

itsid

Moderator
Staff member
Messages
11,563
Reaction score
247
Location
Ruhrpott [Germany]
well the HPM5000B does NOT meet your specs.. (it peaks at 8.5kW roughly and provides 5kW continuous)
which you could do with an ME0907 as well http://www.evdrives.com/product_p/mot-me0907.htm
(a tad cheaper but very reliable)

but to be honest.. I think you massively underestimate the power of a 7kW electric motor.
it's NOTHING like a 7kW engine .. it feels closer to a 20kW engine really ...
since all the torque is right at the first rpm ..

I doubt you need a 15kW peak for a 14yo kid to have some massive fun

there's this somewhat famous yt video of a guy installing a 7kW truck starter (24V)
on a go kart and goes up and down the road a few times.
here:
www.youtube.com/watch?v=C5lp3fP1WKo


Anyways, I think you should judge your power rating by the amount of power you need
just calculate it

and then, reevaluate the motor.
since in the end, less power means less batteries to carry around for the 20min race,
less money to spend etc..

your choice of course, and yes the golden motor seems like a good choice (if you need such power)

'sid
 

redline2097

New member
Messages
5
Reaction score
0
Actually my 4 year old son is running 4,5kw peak power electric diy dirt bike. We just need the cars to be able to compete with 125cc class in power (20kw peak power)

We are using sabvoton 72200 torque based controller with no sin/cos support. So we need hall sensors on the motor side.

https://youtu.be/pKR9zqKcFIc
 

itsid

Moderator
Staff member
Messages
11,563
Reaction score
247
Location
Ruhrpott [Germany]
acceleration wise a 7kW electric motor can surely compete a 20kW 125cc engine;
not in peak power (missing rpm) but since it lacks the gearbox anyways (for good reason)
chances are it's competible all around the track (not just exiting a corner ;))

the one you mentioned in your first post (8.6kW peak) for example is not a bad option not at all
IMHO
And the lust for power is strong.. the downsides for "overpowered" vehicles are plentiful (especially for electric motors)
doubling the amount of batteries to get the same amount of time
will be adding dead weight, which is actually much worse than a missing kW in peak power, when it comes to kart racing ;)

but I see, you want to throw money at it.. awesome.
I'd use a kelly controller and a me0907 (solid 5kW, peaking at maybe 7.5-8 or so)
which as a set is cheaper than a single one of your motors.
install 30kg less batteries (again saving money)
and in the end both karts should be about similarly snappy, speedy and funny :D

just saying...

IDK the sabvoton controllers..
torque based? HOW? current limiting?
well good news, that's basically what all controllers do ;)

sin/cos support ..hall effect sensors on the motor...
soo we talk three phase here? (five? six?..)
Sure, no problem.. kelly can do that too w/o the need for hall effect sensing;
in fact noone really needs hall effect sensing on motors like that at all
(not if you don't need to run the motor at extremely low speeds [less than 20 rpms or so])
All you need is checking the backemf from the other coils to know which phase it's in.
(that'S what most controllers do actually)
Sure, hall effect sensors are more precise and they do work w/o any motor rotation
so if you need to set a motor sped to EXACTLY 2532 rpms or need to run really really slow...
but if you want to go fast and don't mind if it's 2550 or 2560 rpms.. hall effect sensing is BS.

'sid
 

redline2097

New member
Messages
5
Reaction score
0
5kw golden motor + sabvoton 72v 200A (200a from battery, 450A phase) controller combo in bulk is about $550. ~2kwh VCT6 cells battery pack in 80v 24ah configuration costs about $1200 per piece. Thats pretty lightweight powertrain, totaling to about 25kg.

Kelly controller is speed based. So when turning throttle it modulates speed only. This is very harsh in high power motors and its pretty hard to tame. Only compromises can be made. True torque based controller like sabvoton controls the motor torque (amps) when modulating throttle. This allows kart to be operated well in very low speed and when you hit the throttle max it instantly generates the max torque also. With speed base controller you have to choose and favor one.

https://evmc2.wordpress.com/2014/12/05/controllers-speed-vs-and-torque-control/

We are aiming to about 80kmh top speed. We have prototype units with Kelly Controller and 8kw peak motor. But since that Kelly operations on speed mode it isn't kids friendly.
 

itsid

Moderator
Staff member
Messages
11,563
Reaction score
247
Location
Ruhrpott [Germany]
kelly is not speed based.. not at all..

motor controllers I know regulate "percentage of power" via the throttle signal
(puls width modulation... with a hall effect sensor throttle...nevermind ;))

IDK where you got the speed-info from, but thats BS I'm afraid.
There is a difference between PM and brushless controllers (phasing and so on)
but in the end, they always chop the signal.. ALL OF THEM
(I bet incl your sabvoton)

And the difference between torque and speed is time..
so yeah.. technically still BS (torque directly converts to acceleration..acceleration times time.. is speed of course)
And torque is comming from currents electrically..
sooo again, current limiting controllers are what you want (and they're the only type you'll find*)

'sid

*that's a lie.. there are voltage regulating controllers, but few and far apart.. and mostly crap I'm afraid ;)
 

redline2097

New member
Messages
5
Reaction score
0
You can test your Kelly if you have. I have three. And they are not coming to our high kw builds.

For testing you need only lift the wheels up and apply about 20% throttle. Because no load current isn't huge on these motors it should slowly apply Full speed if torque based. Even Kelly set to "torque" mode it reaches only 20% speed with 20% throttle.

In other hand the sabvoton, sevcon etc gains the full speed at 20% throttle like they should. Since they are torque based and controls amps instead of voltage like Kelly.
 

itsid

Moderator
Staff member
Messages
11,563
Reaction score
247
Location
Ruhrpott [Germany]
ramp up time and cutoff is programmable on kelly controllers..
as is load sense (in most)
but nevermind, use the controller you feel most comfortable with.
it'll be fine.

The issue I'm having is solely the misinformation .. motor controllers
like that do basically the same thing no matter what brand no matter what power or voltage..
they ALL toggle the motor on and off (square signal [fullvoltage-fullamps]) within split seconds..
the longer the motor is ON the more power is on the road..
that's all they do, there is no other viable route without wasting battery charge.

Some are better quality, some provide other fuinctions
(like a governor, speed limiter, regenerative braking and so on and so forth)
but the actual motor control is a full power square wave.

And yes, if you forget to install the governor switch, most controllers that use one fall back into safe (kids) mode (reduced signal by ~50-60%)

Again, I don't say you should use a different controller or motor, both of your choices seem like a viable route.
I haven't seen a sabvotons internals and I cannot judge about it's quality,
in fact I haven't even read about their list of features either since I don't care enough as of yet ;)
At first glance.. they should do.

But they do exactly as the kellys do, and those have proven over the years to be always the best bang for the buck (reliability/quality for the lowest price)
that's all why I like to suggest those...

One thing though:
please stop using terms like "torque based or speed based" in this context..
it's simply WRONG and it makes me cringe..
even worse.. kellys do NOT control voltage (like all others they control TIME ;))

And while it's true that you can sense torque (bit of a stretch)
and speed (directly) from a three phase motor
by checking what Amperage is sent to
and what rotational signal is read from the motor..
which makes it possible to either set a controller to govern based on
the amperage or based on the rotational speed.

You can (with a programmable controller) change that with the push of a button (well several key strokes ;))
with most you can disable all governing by the flick of a switch
in any case all of kellys functions canbe disabled AFAIK (with the exception of undervoltage protection IIRC)
Soo with some fiddling it can act indistinguishably from your sabvoton.(which according to the mfg is advertised as 6kW output power!.. a 15kW motor would likely just burn through it's MosFETs in an instant... just saying)


it's still not torque.. it's never really torque..
relative torque perhaps (amps) but surely not controlled torque since that is even with electric motors based on speed.
there's a max amount of torque (at a certain rpm) that's at max amp draw.
and that can be lowered (by reducing the amps) but there is no way to control that other than reducing the amperage [or if it starts stalling ramping it up again]

that's a misconcept I'm afraid and it's a really bad one for advertising motor controllers.

'sid
 

redline2097

New member
Messages
5
Reaction score
0
Please read this: https://www.google.fi/amp/s/evmc2.w.../controllers-speed-vs-and-torque-control/amp/

"Pure speed control will feed 100% of your available torque to the motor to get it up to the “requested” RPM. (Remember now, volts = RPM, so it’s specifying the voltage and letting the current rip until the RPM gets to the target.) Pure torque control dials in the current to feed the motor until it gets to the requested speed. Torque control still has to monitor the speed, and yes, it controls the voltage, but that’s done as a secondary step (to put it in a way that will drive most EEs nuts). It’s a way of dialing in the rotational force until you reach a desired RPM."

I think this is not the best place to get proper information. Back to the Endless-sphere.
 

itsid

Moderator
Staff member
Messages
11,563
Reaction score
247
Location
Ruhrpott [Germany]
endless sphere is a great place if you know whom you're talking to ;)

you cannot feed torque (which is a purely mechanical unit)
with a motor controller (which is a purely electrical unit)
As simple as that.

I think I know what you mean, I think I even understand what Ted wanted to say (which is basically the same thing)
BUT that doesn't make it more "correct" surely it's the wrong terminology.
the gernalisation volt = rpm for example is simply WRONG for most motors on this Planet,
it's not even true for BLDC motors mostly.

And that's what I am complaining about..
speed or torque BASED controller there are NONE!

All regulate Amp (Power really.. but generally considered as Amp control...)
Most simple controllers don't care about anything and
just use the pedal signal as the ONLY input, no ramping no governing, no nothing.
since it's rather basic, they usually come with nothing but undervoltage protection to save the batpack from dying.

advanced controllers (well somewhat advanced)
come with an additional overvoltage protection to save the motor from being fried,
and some other "protection" circuits and code.. like overcurrent protection, brake signal (to turn off the motor once the brake is engaged) emergency switches and so on.

More advanced controllers add a ramp up sequence which allows "smooth take off"
and/or a governor code to the mix limiting the max power to a certain amount (say 80%)

even more advanced controllers are programmable (in which case you can set/reset the ramp up and limiting factors)

and the peak of those programmable controllers add further input signals,
like motor temperature, motor speed and current Amp draw.

And that's where your misconception starts.
They too just toggle the MosFETS on and off in a matter of split seconds,
switching the motor on and off (again in split seconds)
it's a square wave... hook your controllers up to an oscilloscope and you'll see the signal

Now, as I said.. yes..
some modulate on/off time using the rotational speed (what you and Ted call speed controllers)
as a comparator value
(ONLY! works on BLDC motors, or motors with known quantity of hall effect sensors)
the downside of that is.. max rotational speed is an unknown value!
keep in mind that controllers do NOT know the motor attached, some can test the motor attached, most don't dare to fire a 7kW motor just to know how fast it could turn ;)

The same holds true for those that don't care about rotational speed (what you and Ted call Torque controllers)
they just don't re-modulate the signal based on rotational speed.

And here's the thing.. while surely all BLDC controllers do read the speed signal somehow (hall effect or back emf from disengaged coils)
IF they use that information for remodulating the Powersignal is SOLELY UP TO YOU on a programmable controller.
And thus... while OOTB there might be a differnce between the behavious or the two controllers,
after you set them up to your needs/likings and reprogrammed them accordingly,
there is no difference any longer.
Both will behave exactly the same way, both will put out the exact same signal (one signal might be messier than the other, one programming interface might be better than the other, sure.. but that's it)

And again NONE of those controllers ever control the voltage..
they always control the power (V*A)
it's a matter of misreading the information provided ..
since the signal is toggled at a very high rate (in the kHz) there is not much equipment to read the signal (an oscilloscope is the one thing I can think of)

a multimeter for example will not read the peak voltage .. especially not when the power out isn't set to 100%
thus it reads a drop in voltage (it's averaging over a small amount of time [a thousand times to long])
even Flukes tend to fail at that task more often than not.

And to sum it up..
a controller does NOT know the motor, neither it's peak rpm nor it's peak torque
peak rpm is dangerous to test (for the controller not knowing if it's save to ramp the motor all the way up)
peak torque is IMPOSSIBLE to test for the controller (since there's no dyno atttached)
And thus... it should never be called torque or speed based.

When you're over at endless sphere.. ask the guys who BUILD motor controllers,
not just the ones who BUY them about how they work.

Once you understand how a MosFET works and how it is toggled, you will surely understand what I'm trying to say.

'sid
 
Status
Not open for further replies.
Top