Overview
ECM’s PCB stator technology has been identified by international e-mobility companies as having unique, advantageous characteristics to support the growing demand for longer range ebikes.
These companies require drive solutions with increased power density. To test the impact of PCB stator technology, ECM collaborated with a German e-vehicle company to design and prototype two unique next generation e-bike mid-drive solutions.
Benefits of PCB Stator Technology for e-bike mid drive solutions
ECM’s PCB stator Technology and PrintStator’s design capabilities add considerable value to e-bike mid drive systems. The superior power density and high efficiency of ECM solutions allow for an extended battery life and range for integrated systems. Less mass means e-bikes will have capacity for additional battery modules, further extending their range. An ultra thin form factor and compact envelope allow these motors to integrate seamlessly as mid-drive motors without interfering with passenger comfort or other mechanical components. Further, ECM’s robust design contributes to increased passenger safety. Fully encapsulated motor windings prevent insulation failure and the totally enclosed case design allows our solution to be durable under extreme conditions. ECM’s motors are acoustically quiet, enhancing the ride experience.
“The compact design enables not only excellent handling but also easy, elegant integration into bike frames or LEVs and E-cargo bikes — no problem either, thanks to the huge power reserves and a modular concept for different performance classes.”
Representative, German EV Company
Results
ECM designed and prototyped two e-bike mid-drive solutions integrated with PCB Stator technology; the first for increased power density and the second for efficient power consumption.
The first mid-drive provided twice the peak power output as the legacy drive without increasing motor volume or mass. ECM’s motor was only 1.91” thick, weighed 1.5kg, and produced 1kW of peak power compared to the bike’s legacy 500W peak motor.
ECM’s second mid-drive solution, with a peak power of 550W, utilized the same magnet mass as the 1kw drive. Magtrol tests on this 1.85” thick, 2kg prototype revealed the motor’s high efficiency across a large range of operating points. Remaining above 85% efficient from 230W to 550W, this mid-drive offers efficient power consumption while accelerating. ECM is currently collaborating with this company in an effort to incorporate these benefits into larger electric vehicles.
Next Steps
ECM is expanding its catalog of solutions beyond e-bike mid drives and integrating PCB stator technology into a variety of e-mobility applications including electric cars, wheelchairs and scooters.
High power density, increased durability, reduced weight, and a slim form factor are a few of the many benefits when a motor solution is built with an ECM PCB stator, making the technology valuable for almost any application.
To find out more about e-mobility applications, check out this interview ECM’s Vice President Robert Luchars took part in for Design World.
To discuss the benefits of ECM’s PCB stator technology within your product line, please email us at info@pcbstator.com or visit pcbstator.com/design-your-own to learn more about our 5-step integration process.
