Team Crack Platoon

Rajshahi University of Engineering &Technology,

Rajshahi 6204

Electric Vehicle Motor and Motor Controller Selection Report

Team Information
Group B

Team Members:

• Mohammad Sakhawat Hossen (2108052, MTE)

• Faiaze Ahmmed Rezvi (2108051, MTE)
• Proma Sarker (2110049, ECE)
• Shadman Zaman (2210018, ECE)
• Mohammad Rokibul Hasan Rakib (2208017, MTE)

Table of Contents
Electric Vehicle Motor and Motor Controller Selection Report ...................................................... 1
Team Information ............................................................................................................................. 1
Introduction ....................................................................................................................................... 2
Motor and Motor Controller Calculations ..................................................................................... 2
Circuit Diagram and Powertrain Design ........................................................................................ 4
Motor and Motor Controller Selection ........................................................................................... 7
Battery Configuration ...................................................................................................................... 9
Sourcing and Procurement Process ............................................................................................... 10
Cost Analysis.................................................................................................................................... 11
Conclusion ....................................................................................................................................... 12

1
Introduction
This report outlines the selection and design process for an electric vehicle (EV) powertrain
system tailored to meet Formula Student regulations. The project aims to achieve optimal
performance, efficiency, and compliance by carefully analyzing and selecting components,
including the motor, motor controller, and battery system.

Through detailed calculations and a structured procurement process, the team identifies
components that not only satisfy the technical specifications but also ensure cost-
effectiveness. By integrating advanced technologies such as regenerative braking and
efficient power management, this design demonstrates a comprehensive approach to building
a competitive Formula Student EV.

The report details the calculations, component justifications, circuit design, sourcing
strategies, and cost analysis, culminating in a robust and reliable powertrain solution.

Motor and Motor Controller Calculations

Electric vehicles (EVs) rely on precise and efficient powertrain systems to meet their
performance requirements. To achieve the design objectives for the given EV specifications,
the motor and motor controller were chosen carefully based on detailed calculations and
engineering analysis.

Specifications

The EV design criteria provided the following specifications:

• Vehicle Weight: 300 kg (including the driver)

• Torque Range: 20–85 Nm
• RPM Range: 2000–5500
• Max Speed: 80 km/h
• Motor Power Range: 8–15 kW
• Motor Efficiency: 91%
• Single Charge Runtime: 40 minutes
• Accumulator Voltage: 72V

These specifications guided the selection process, ensuring the components could deliver
optimal performance under various driving conditions.

Power Calculation

To determine the power requirements of the motor, the relationship between torque and
rotational speed was used. The power equation is given by:

P=T⋅ω/9550

Where:

• P = Power (kW)
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 • T = Torque (Nm)
• ω = Rotational speed (RPM)

Case 1: Maximum Torque and RPM

For the maximum torque of 85 Nm and maximum rotational speed of 5500 RPM:

85∗5500
Pmax = ≈ 49 kW
9550

This represents the peak power requirement during high-demand scenarios, such as
acceleration or hill climbing.

Case 2: Minimum Torque and RPM

For the minimum torque of 20 Nm and minimum rotational speed of 2000 RPM:
20∗2000
Pmin= ≈ 4.2 kW
9550

This value reflects the power needed during low-speed, low-load conditions.

Continuous Power Range

Given the vehicle’s operating conditions, a motor with a continuous power range of 8–15 kW
is ideal. This range ensures sufficient power for standard driving while maintaining efficiency
and thermal stability.

Efficiency Consideration

Motor efficiency plays a crucial role in minimizing energy losses and extending battery life.
The chosen motor has an efficiency of over 91%, ensuring that most of the electrical energy
from the battery is converted into mechanical energy.

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Circuit Diagram and Powertrain Design
This block diagram illustrates the powertrain system for an FSAE electric vehicle, detailing the
flow of energy and control signals from the battery to the motor. Each component is selected
and positioned to ensure compliance with safety and performance requirements.

Figure 1: Electric Vehicle Powertrain Overview

Fig 1: Electric Vehicle Powertrain Overview

Battery Pack (Accumulator)

A. Role: Supplies electrical energy to the entire vehicle.
B. Key Features:
a. Composed of Lithium-ion cells (e.g., 3.7V per cell).
b. Configured in series and/or parallel to achieve the required voltage and capacity.
c. Includes fuse protection to prevent overcurrent.

Battery Management System (BMS)

A. Role: Monitors and protects the battery pack.
B. Key Features:

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 a. Ensures proper charging and discharging of cells.
b. Protects against over-voltage, under-voltage, over-temperature, and
overcurrent.
c. Balances cell voltages for optimal performance.

Precharge Circuit
A. Role: Prevents high inrush current from damaging components like the inverter or
capacitors.
B. Key Features:
a. Gradually charges the inverter's internal capacitors to avoid sudden surges.
b. Uses a resistor and relay combination.
c. Activates before the main power relay.

Inverter (Motor Controller)

A. Role: Converts the DC voltage from the battery to controlled AC voltage for the motor.
B. Key Features:
a. Controls motor speed, torque, and direction based on inputs (e.g., from APPS).
b. Includes fault detection and communicates with other vehicle systems.

Accelerator Pedal Position Sensor (APPS)

A. Role: Measures the driver’s throttle input and sends a control signal to the inverter.
B. Key Features:
a. Outputs a voltage signal (typically 0–5V) proportional to the pedal position.
b. Ensures precise control of the motor’s power output.
A dual output APPS supplied with two different voltages (5V and 3.3V) is used to
generate two signal outputs. A microcontroller is used to read the signals. The two
signals go through a signal plausibility check to determine if the two signals deviation
is less than 5%. If greater than 5%, zero torque will be requested to motor controller.
The signals are also checked to make sure they are not out of range. If signals are out
of range, zero torque will be requested to motor controller. Based on the APPS signal
a percent max torque is determined, known as the pedal requested torque. The pedal
requested torque signal is limited based on the power limit of the accumulator, vehicle
speed, and traction. A final torque request is created, and the signal is sent to the motor
controller. If there is no new torque command received by the motor controller (loss of
communication) the motor controller will stop operation.

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 Fig 2: Torque Control Signal Path

Motor
A. Role: Converts electrical energy into mechanical energy to drive the vehicle.
B. Key Features:
a. A BLDC Motor is used.
b. Delivers high efficiency and precise torque control.
c. Operates within the specified RPM and torque range.

Shutdown Switch
A. Role: Disconnects power from the entire electrical system (high voltage and low
voltage) during emergencies or faults to ensure safety.
B. Key Features:
a. Provides manual and automatic activation for emergency isolation.
b. Positioned between the battery pack and other components (e.g., inverter).
c. Integrated with fault detection systems to trigger shutdown when necessary.

High Voltage Disconnect (HVD)

A. Role: Manually isolates the high-voltage system during maintenance or emergencies.
B. Key Features:
a. Complies with FSAE safety rules.
b. Located in an accessible position in the vehicle.

DC-DC Converter
A. Role: Steps down high voltage from the main battery to 12V for low-voltage systems.
B. Key Features:
a. Ensures reliable power for the electronics and auxiliary components.

Relays (AIR 1, AIR 2) and Contactors

A. Role: Control the flow of high and low voltage in the system.
B. Key Features:
a. High-current relays handle power distribution.

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 b. Controlled by low-voltage signals for safety and efficiency.

Brake System Plausibility Device (BSPD)

A. Role: Ensures the motor power is cut off if the accelerator and brake pedals are applied
simultaneously.
B. Key Features:
a. Enhances safety.
b. Integrates with the inverter/motor controller.

Motor and Motor Controller Selection

Selecting the appropriate motor and motor controller is essential for achieving the desired
performance and efficiency. The components were chosen based on their compatibility with
the design specifications and their proven reliability in similar applications.

Motor: Golden Motor HPM10KW

The Golden Motor HPM10KW was selected due to its

robust performance and suitability for EV applications. Its
key features include:

• Power: 10 kW (continuous), 15 kW (peak)

• Torque: 85 Nm
• Efficiency: >90%
• Voltage: 72V
• RPM Range: 3000–6000

This motor meets the torque and power requirements of

the EV, providing excellent performance under various
conditions.
Figure 3: Golden Motor HPM10KW

Motor Controller: Kelly KLS7230S

The Kelly KLS7230S motor controller was chosen for its

versatility and advanced features. Its specifications include:

• Voltage Range: 24–72V

• Current: 200A
• Programmable: Supports customizable settings for
optimal performance
• Regenerative Braking: Enables energy recovery
during braking
Figure 4: Kelly KLS7230S

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This controller is fully compatible with the Golden Motor HPM10KW and ensures efficient
power delivery and control.

Other Potential Options and Why They Were Not Chosen

Motor: ME1304

• Power: 12 kW (continuous), 18 kW (peak)

• Torque: 70 Nm
• Voltage: 72V
• RPM Range: 4500–5500
• Reason Not Chosen:
o Slightly lower torque compared to the Golden Motor HPM10KW.
o Higher peak power may lead to increased thermal management requirements,
complicating the design.

Motor Controller: Sevcon Gen4 Size 6

• Voltage Range: 48–72V

• Current: 275A
• Reason Not Chosen:
o More expensive compared to Kelly KLS7230S.
o Over-engineered for the power range of this EV, leading to unnecessary cost
increases.

Motor: QS Motor 205 V3

• Power: 8 kW (continuous), 14 kW (peak)

• Torque: 65 Nm
• Voltage: 72V
• Reason Not Chosen:
o Lower torque compared to the HPM10KW.
o Limited availability and longer lead times.

Motor Controller: VESC 75/300

• Voltage Range: Up to 75V

• Current: 300A
• Reason Not Chosen:
o While highly configurable, the open-source design requires extensive tuning,
increasing development time.
o Less robust documentation and support compared to Kelly controllers.

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Battery Configuration
An efficient battery configuration ensures optimal motor
performance, supports peak power demands, extends range,
and enhances safety while preserving battery lifespan and
minimizing costs.

Cell Form Factor

The 18650 form factor is preferred for FSAE cars due to its high
energy density, cost-effectiveness, modularity, and reliability.
Its standardized size allows for flexible pack designs, efficient
thermal management, and compatibility with high-performance
demands. Additionally, its widespread availability and
established safety features make it an ideal choice for our
budget-conscious team. Figure 5: 18650 Battery Pack

Battery Calculation
To achieve 72V Accumulator Voltage,
72
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑆𝑒𝑟𝑖𝑒𝑠 𝐶𝑒𝑙𝑙𝑠 = = 19.459 ~ 20
3.7
Considering the average cell capacity of 3Ah for each cell, we need a runtime of 40 min.
The energy required for our selected motor (Model: HPM-10KW -- High Power BLDC Motor)
can be found by:
𝐸𝑛𝑒𝑟𝑔𝑦 = 𝑃𝑜𝑤𝑒𝑟 × 𝑅𝑢𝑛𝑡𝑖𝑚𝑒
40
 𝐸𝑛𝑒𝑟𝑔𝑦 = 10000 ×
60
 𝐸 = 6666.67𝑊ℎ
But we need to consider the motor and motor controller efficiency. The adjusted energy can be
found by the following equation:
Rated Power (W) × Operating Time (h)
Adjusted Energy (Wh) =
𝜂motor × 𝜂controller
2
10000 ×
 Adjusted Energy (Wh) = 0.91 × 0.99
3
= 7400 Wh

𝐴𝑑𝑗𝑢𝑠𝑡𝑒𝑑 𝐸𝑛𝑒𝑟𝑔𝑦
𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 =
𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝑉𝑜𝑙𝑡𝑎𝑔𝑒
7400
 𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = = 102.778 ~ 103𝐴ℎ
72
If we consider the well health of the cells, then we must take the Depth of Discharge (DoD) for
the battery to be 80%.

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Thus, the Effective capacity of the battery is:
103
𝐸𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = = 128.75𝐴ℎ
0.80
128.75
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑃𝑎𝑟𝑎𝑙𝑙𝑒𝑙 𝑆𝑡𝑟𝑖𝑛𝑔𝑠 = = 42.92 ~ 43
3
The configuration for the accumulator for optimal power is therefore 20S43P.
𝑇𝑜𝑡𝑎𝑙 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐶𝑒𝑙𝑙𝑠 = 20 × 43 = 𝟖𝟔𝟎 cells
𝑅𝑎𝑡𝑒𝑑 𝑃𝑜𝑤𝑒𝑟
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐹𝑙𝑜𝑤 =
𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 × ηmotor
10000
 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐹𝑙𝑜𝑤 = = 152.63 ~ 153𝐴
72 × 0.91
This configuration will allow the motor to run efficiently without any problem under standard
rated power.

Sourcing and Procurement Process

To ensure the quality and reliability of the selected components, reputable vendors were
chosen for sourcing.

Vendor Details

1. Motor: Golden Motor HPM10KW (Golden Motor)

2. Motor Controller: Kelly KLS7230S (Kelly Controller)

Procurement Steps

▪ Specification Verification: Confirm that the components meet the EV’s design
criteria.
▪ Vendor Communication: Contact vendors to inquire about product availability and
delivery timelines.
▪ Cost Estimation: Obtain quotes for the components, including shipping and taxes.
▪ Order Placement: Place orders with selected vendors.
▪ Quality Assurance: Inspect components upon delivery to ensure they match the
specifications.

By following this process, the team ensures that the components are sourced efficiently and
meet the required standards.

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Cost Analysis
A. Motor:
Golden Motor HPM10KW
Quantity: 1
Unit Price: $950
Vendor: Golden Motor

Vendor Details:
Address: 19231 Van Born Rd, Allen Park, MI 48101, USA
Tel: +1-800-717-1324
Website: https://goldenmotor.bike/
Email: admin@goldenmotor.ca

B. Motor Controller:
Kelly KLS7230S
Quantity: 1
Unit Price: $235
Vendor: EV Components
Vendor Details:
Address: #8, Dachong Road, Dashi 511430, Panyu District, Guangzhou,
China
Order & Business Email: contact@evcomponents.com
Shipping Email: support@evcomponents.com
Complaint & Store Master Email: info@evcomponents.com
C. Battery System:
Battery Cells (quantity 700 cells), Battery Management System (BMS):
Estimated cost around $2000

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Conclusion
The selected motor and motor controller meet the specified requirements for the EV and adhere
to Formula Student regulations. The proposed powertrain design ensures high efficiency,
reliability, and safety. The inclusion of regenerative braking further enhances the vehicle’s
performance and energy efficiency.

Detailed calculations, sourcing links, and cost analysis validate the component selection
process. By combining robust components with an optimized design, the EV is well-equipped
to deliver excellent performance under various conditions.

This report demonstrates a comprehensive approach to designing and implementing a high-

performance powertrain system, ensuring success in the Formula Student competition.

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