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Design, analysis and comparative study of Hub motor for an electric bike

Conference Paper · January 2021

DOI: 10.1049/icp.2021.1179

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 Michael Faraday IET International Summit: MFIIS-2020, October 03 – 04, 2020, Kolkata, India
(Paper ID: 66)

Design, analysis and comparative study of Hub motor for an electric bike

Sandeep Kumar Chawrasia 1*, Aakash Das 2, Chandan Kumar Chanda 3, Sumit Banerjee4
1
Electrical Engineering department, Indian Institute of Engineering Science and Technology, Shibpur, Howrah,
India.
2
Electrical Engineering department, Indian Institute of Engineering Science and Technology, Shibpur, Howrah,
India.
3
Electrical Engineering department, Indian Institute of Engineering Science and Technology, Shibpur, Howrah,
India.
4
Electrical Engineering Department, Dr. B C Roy Engineering College, Durgapur, India.
*sandeep.chawrasia9@gmail.com

Abstract: At present, the inner rotor or outer rotor BLDC motors are generally used in the electric motorbikes. However, the
outer rotor BLDC motors are fast finding applications in wheels of an electric bike for fewer core losses and higher
efficiency. But still, the speed of the bikes available in the market is quite low or if people go for some more top speed
electric bikes that are very costly. So, in this work, two high speed 36 slots, 24 poles exterior rotor motors are designed for
the high-speed, smooth operation of an electric bike. The design of the Hub motors is done based on the hand calculations
of the design parameters. Then the RMxprt models are designed using those calculated data, and various iterations are
performed for getting the required design. But here, just the final design sheets and plots are shown. Also, the RMxprt
models are converted to Maxwell 2D design model for further analysis and accurate and precise design. This paper consists
of a comparative study of both the designs based on these calculations, results and graphs. This research work gives a clear
concept to the reader for selecting a suitable model according to their applications.

designed models are 2.4 kW motors with a rated speed of

1. Introduction
A brushless dc motor is a motor devoid of any
brushes, slip rings, or a commutator. The current changes its
polarity every time a magnet passes through the pole for
providing a unidirectional torque. The rotor of a BLDC
motor is excited by a magnetic field produced by the
permanent magnets of the motor. The flux density waveform
of the BLDC motor is almost trapezoidal, although it
depends upon the shape of the magnets, winding layout and
pattern of the permanent magnets. The BLDC motors come
with two types of rotor configurations, i.e., the inner rotor
and the outer rotor or out runner [1]. The designed models
are based on the out-runner configuration. In an out-runner
(exterior rotor configuration), the rotor completely encloses
the stator, and consequently, the diameter of the rotor is more
than the stator.
Compared to an inner-rotor configuration, the outer-
rotor configuration can produce a similar or higher torque
using lesser electrical and magnetic quantities. The three-
phase version of the outer rotor configuration helps in
providing a bi-directional power flow, fewer losses, and a
much higher overall efficiency. As the inertia of these motors
is very high hence considerable lengths of the stator and the
rotor should be selected, most preferably in the range of 70 to
100 units [1]. The BLDC motors find its applications in
Indian Drive cycle [2], in renewable energy applications such
as solar-powered vehicles [3], in wind farms and wind vanes
for the generation of electricity and driving BLDC motor
vehicles [4] and in aerospace engineering, for controlling the
motion of motors and in positioning and actuation systems
[5].
Here, two models with different voltage ratings are
designed using RMxprt and Maxwell 2D. The first model
operates on a voltage rating of 120 volts, and the second
model operates at a voltage rating of 72 volts. Both the
1000, which provides the high speed to the electric bike
(nearly 100km/h). Moreover, the designed models have
much higher efficiency, making them almost invulnerable to
the effect of a large number of losses that are experienced by
vehicular motors.
In-wheel motors are (Hub-motors) nowadays in
demand for the application in vehicles because of their high
starting torque and less amount of generated losses. These
characteristics of this motor extend the km-range of the
electric bike, making them accessible and replacing the fuel
operated motorcycle with the electric one [6].
The models encompass a magnetic thickness of 4 mm,
which makes them cost proof. The designed models have a
slot fill factor of less than 40 percent, which provides less
heating, i.e., excellent thermal stability, which further
reduces the cost. The models can achieve very high speed
and can subsequently be incorporated in racing bikes too.
2. Various stages for motor design
In the flowchart (Fig.1.), the various important stages
for motor design are shown and out of those the most
important stages are explained in the coming sections.
The first stage where the application requirements are
calculated is also very important for the design. From this
calculation only, the motor specifications are determined.
But before those calculation, some required data (Bike
Specifications) must be known to make the calculations
possible and simple. So, here those data are calculated (some
are assumed with proper estimation using data of other bikes)
and tabulated below (Table 1):

1
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(Paper ID: 66)
3. Design parameter calculations
In this section, calculations of various parameters
required for designing both the models are discussed.
Designing of the motors require a lot of considerations for
the stator and rotor parameters, which must be calculated
before starting the designing of the motors. In this section,
the stator and rotor sizing, the air gap length calculations, and
the winding parameter calculations for motor designing are
discussed elaborately. The winding parameter calculations
are the most important of the lot because based on this, the
total number of conductors per slot can be determined, which
has a significant effect on the cost of our machines.
3.1. The stator and the rotor size

The torque of the outer rotor brushless dc motor

depends on the average shear stress at the surface of the
rotor. The average torque related to shear stress considering
unit rotor surface area can be written as:

ߨ ଶ
ܶൌ ‫ߪ݈ ܦ‬ሺͳሻ
ʹ
Where D is the rotor inner diameter. The shear stress
(ߪ) is given as a product of the magnetic loading (B) and the
electric loading (A), hence the formula for shear stress is:
ߪ ൌ ‫ܣܤ‬ሺʹሻ
Usually, the value of B and A taken as 0.5 - 0.6T and
20 - 40 A/mm respectively. Considering B = 0.55 T and A =
30 A/mm, using (2) the calculated value of σ will be 16.5
KN/m2. Now taking l = 80mm and using (1) the calculated
value of the rotor inner diameter will be nearly 120mm, i.e.,
D = 120mm. Furthermore, to calculate the stator outer
diameter, the following formula can be used:
‫ ܦ‬ൌ ‫ܦ‬௦ ൅ ʹ݈௚ ሺ͵ሻ
Fig. 1. Flowchart of motor design stages [7]. Where Ds and ݈௚ are the stator outer diameter and the
air gap length, respectively.
Table 1 Bike specifications 3.2. Air gap length calculation
Specifications values
Gross weight (M) 150 kg With the help of power factor, overload capacity,
pulsation loss, unbalanced magnetic pull, cooling and noise,
Top speed (v) 100 km/hrs. the air gap length can easily be calculated using the formula:
Speeding (0-100 kmph.) In 25 seconds ݈௚ ൌ ͲǤʹ ൅ ʹξ‫݈ܦ‬ሺͶሻ
Tyre size 120 / 80 R 17 Considering D as 120 mm and l as 80 mm in (4), the
calculated value of air gap length is 0.5 mm. Using (3), the
Maximum. Grading (α) 100 value of the stator outer diameter is obtained as Ds = 119mm.
coefficient of rolling resistance (Crr ) 0.01 3.3. Calculation of winding parameter

At the first stage of the design algorithm, the results The main task of winding parameter calculation is
(Motor specifications) of various mechanical calculations finding the total conductors per slot for designing the motors.
and terminologies are tabulated below. However, some other parameters also come into play while
developing the motor models. They are:
Table 2 Motor specifications 3.3.1. Coil pitch: It is greatest integer value of the slots to
pole ratio, and the value must always be 1 or more. Here
Specifications values slots to pole ratio value is 1.5, so coil pitch is taken as 1.
Power 2.4 kW
3.3.2. Conductors per slot: The conductors per slot can
Torque 23 Nm be calculated from the formula, which depends upon the
ratio of total ampere conductors and circumference of air
Speed 1000 rpm gap. The formula is given by:
2

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 Michael Faraday IET International Summit: MFIIS-2020, October 03 – 04, 2020, Kolkata, India
(Paper ID: 66)
ܼ‫ܫ‬ else various changes can be made in the initial data and
‫ܣ‬ൌ ሺͷሻ again, the results are verified until the desired output is
ߨ‫ܦ‬௦
Where, Z= total number of conductors, Ds = stator obtained.
outer diameter and I is the current rating. Here the design sheet and the plots for both models
are given below, and the explanations and discussions of
Winding parameter calculation for model-I: these results (plots) and design sheet-data are given in
Putting the value of A as 30 A/mm, rated current I as 20 section-6 and section-7.
Amp and the stator outer diameter in (5), the approximated
value of Z = 467. With 36 slots, the slots per conductor are Zs Table 3 Final design-sheet for Model-I
=12.972. Also for a double layer winding, the total
conductors per slot must be integer and multiple of 2, so it is Rated Data
better to take Zs = 14.
Output Power (kW) 2.4
Winding parameter calculation for model-II:
Similarly, Putting the value of A as 30 A/mm, rated current I Voltage (V): 120
as 33 amperes, and the stator outer diameter in (5), the
calculated value of Z=283. With 36 slots, the approximated Poles 24
value of slots per conductor Zs = 8.
Speed (rpm) 1000
3.4. Sizing of slots
Stator Data
Slot sizing can be determined from the parameters
such as slot fill factor, slot area, area of copper, and the Stator Slots 36
insulation area. The formula that combines the above
Stator Outer Diameter (mm) 129
parameters can be written as:
ሺ‫ܣ‬௖  ൅  ‫ܣ‬௠ ሻ Stator Inner Diameter (mm) 25
‫ܣ‬௦ ൌ ሺ͸ሻ
‫ܨ‬௦ Stator Core Length(mm) 80
Where, As is the slot area, Ac is the copper area, Fs is
Steel Type steel_1010
slot fill factor, and Am is the insulation area.
3.4.1. Slot sizing of model-I: In model-I, considering Diameter of wire (mm) 0.302
strands per conductor as 15 and each strand having a wire
Slot Fill Factor (%) 36.8911
diameter of 0.302 mm, the copper area is calculated by using
the formula: Rotor Data
‫ܣ‬௖ ൌ ܼ݊௦ ݀ ଶ ሺ͹ሻ
Where n is the number of strands, and d is the Length of Air Gap (mm) 0.5
diameter of the wire. Now putting the values of n, Zs, and d in Rotor Outer Diameter (mm) 175
(7), the copper area is calculated as 46.514 mm2. Ac = 46.514
mm2. Now, putting the slot fill factor as 39% and the Rotor Length (mm) 80
insulation area (Am) as 16 mm2 in (6), the net slot area is
calculated as: As = 161 mm2. Magnet Thickness (mm) 4
According to the slot area value, (slot depth and slot Magnet Type NdFe35
width) can be determined. Hence, on average we can take
slot depth 23 mm, and slot width 7 mm. Full-Load Data
3.4.2. Slot sizing of model-II: In model-II, considering Average Input Current (A) 21.6731
strands per conductor as eight and each strand having a wire
diameter of 0.511 mm and putting the values of n, Zs and d in Specific Electric Loading (A/mm) 32.2338
(7) the copper area is calculated as 37.6 mm2. Ac = 37.6 mm2.
Now, taking the slot fill factor as 43% and the insulation area Windage and Frictional Loss (W) 19.9998
(Am) as 7 mm2 in (7), the net slot area is As = 102 mm2.
Copper Loss (W) 175.532
Similar to model-I, using above calculations, on
average we can take slot depth as 14 mm, and slot width as Total Loss (W) 200.425
7mm [7].
Output Power (W) 2400.35
4. RMxprt design Input Power (W) 2600.77
RMxprt design is the primary step for designing any
motor models. It is a dedicated software package for the Efficiency (%) 92.2936
determination of simulation of electrical machines [8]. Data
Rated Speed (rpm) 999.994
required to create a RMxprt design can be obtained using
initial hand calculation. Then a basic design can be made, Rated Torque (Nm.) 22.9217
and the result of the designed model can be verified and
checked. If it is matching with the desired one, then it is ok, Locked-Rotor Torque (Nm.) 358.216
3

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(Paper ID: 66)
Table 4 Final design-sheet for Model-II
4.1. RMxprt curves and Plots for model-I: Rated Data
Output Power (kW) 2.4
Voltage (V): 72
Poles 24
Speed (rpm) 1000

Stator Data
Fig. 2. Plot of efficiency vs. speed.
Stator Slots 36
Stator Outer Diameter (mm) 129
Stator Inner Diameter (mm) 25
Stator Core Length(mm) 80
Steel Type steel_1010
Fig. 3. Plot of output power vs. speed. Diameter of wire (mm) 0.511
Slot Fill Factor (%) 45.2001

Rotor Data
Length of Air Gap (mm) 0.5
Rotor Outer Diameter (mm) 175

Fig. 4. Plot of output torque vs. speed. Rotor Length (mm) 80

4.2. RMxprt curves and Plots for model-II: Magnet Thickness (mm) 4
Magnet Type NdFe35

Full-Load Data
Average Input Current (A) 36.0075
Specific Electric Loading (A/mm) 27.8681
Windage and Frictional Loss (W) 19.9863
Fig.5. Plot of efficiency vs. speed. Copper Loss (W) 164.274
Total Loss (W) 192.223
Output Power (W) 2400.32
Input Power (W) 2592.54
Efficiency (%) 92.5855
Rated Speed (rpm) 999.656
Fig.6. Plot of output power vs. speed. Rated Torque (Nm.) 22.9292
Locked-Rotor Torque (Nm.) 379.313

Fig. 7. Plot of output torque vs. speed.
5. Maxwell 2D design
After the desired result are obtained from RMxprt
models, the RMxprt designs are converted to their respective
Maxwell 2D design for further analysis like the saturation of
the core, the torque, etc., and to get a more precise result.
Here, for both the models, the different plots obtained from
Maxwell 2D design are given below:
4

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(Paper ID: 66)

Fig. 8. Magnetic B plot for model-I.

Fig. 9. Magnetic B plot for model-II.

Fig. 10. Plot of torque vs. time for model-1. Fig. 11. Plot of torque vs. time for model-II.

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 Michael Faraday IET International Summit: MFIIS-2020, October 03 – 04, 2020, Kolkata, India
(Paper ID: 66)
6. Comparative analysis 8. References
Based on the two models, the comparative analysis
[1] Design of Brushless Permanent Magnet Motors by J. R. Hendershot,
between the both models can easily be done based on some and T. J. E. Miller.
critical factors. The comparative analysis table is shown [2] Prasun Mishra, Suman Saha, and H. P. Ikkurti, "A Methodology for
below: Selection of Optimum Power Rating of Propulsion Motor of Three-
Wheeled Electric Vehicle on Indian Drive Cycle (IDC)", in
Table 5 Comparative analysis table. International Journal on Theoretical and Applied Research in
Mechanical Engineering [IJTARME], Volume 2, Issue 1, pp. 1, 2013
Parameters Model-I Model-II
[3] Immanuel Alphonse, Dr. S. Hosimin Thilagar, F. Bright Singh,
Rated Voltage(V) 120 72 "Design of Solar Powered BLDC Motor-Driven Electric Vehicle", in
International Journal of Renewable Energy Research, Volume 2, No.
Average Input Current(A) 21.6731 36.0075 3, 2012.

Diameter of wire (mm) 0.302 0.511
Stator Slot Fill Factor (%) 38.8149 43.4009
Total Loss (W) 200.425 192.223
Efficiency (%) 92.3 92.6
As Model-I is designed for higher voltage the input
current will have comparatively lower value. So, for Model-
I comparatively thinner wire can be used in the winding
which decreases the slot fill factor. Also, Model-I will have
very less heating effect it increases the overload capacity if
the machine, Hence Model-II will have less overload
capacity.
From Fig. 8. and Fig. 9. It can be seen that Model-I is
having comparatively less saturation in the core, this is
because it has less electric and magnetic loading than that of
Model-II.
Based on the Maxwell 2D design of the two models,
the ripple in toque is much lesser in Model-II than in Model-I,
this is due to comparatively high numbers of winding. As
torque ripple can be reduced by increasing the number of
windings and the number of poles but here both the machines
are of 24 poles hence windings are increased in Model-II [9].
[4] Saeed Masoumi Kazraji, Saheb Khanabdal, Ramin Bavil Soflayi,
Mehran Sabahi, "A Micro-Scale Wind Turbine Fed BLDC Motor for
Electric Vehicle Drive Application", in International Journal of
Renewable Energy Research, Volume 4, No. 1, 2014.
[5] Shimon Y. Nof; Wilbert Wilhelm; H. Warnecke (1997). Industrial
Assembly. Springer Science & Business Media. p. 174. ISBN 978-0-
412-55770-5.
[6] Chunhua Liu, K. T. Chau, and J. Z. Jiang. “ A Permanent-magnet
Hybrid In-wheel Motor Drive for Electric Vehicles”, IEEE Vehicle
Power and Propulsion Conference (VPPC), Harbin, China,
September 3-5, 2008.
[7] S. K. Chawrasia, C. Kumar Chanda and S. Banerjee, “Design and
Analysis of an In-Wheel Motor for an Electric Vehicle," 2020 IEEE
Calcutta Conference (CALCON), Kolkata, India, 2020, pp. 351-355,
DOI: 10.1109/ CALCON49167. 2020. 9106538.
[8] ANSOFT RMXPRT Manual.
[9] H. V. Patel and H. Chandwani, "Notice of Violation of IEEE
Publication Principles: Review paper on Torque Ripple Mitigation
Techniques for PMBLDC Motor," 2017 International Conference on
Current Trends in Computer, Electrical, Electronics and
Communication (CTCEEC), Mysore, 2017, pp. 669-674, doi:
10.1109/CTCEEC.2017.8455143.

7. Conclusion
In this paper, two motor having high-efficiency and
high-torque are designed using RMxprt and Maxwell 2D.
After the completion of basic motor design using RMxprt,
the Maxwell 2D design is created to provide a more precise
and error-free result. The motor designing is done based on
parameter calculations and assumption which have been
adequately explained. Different graphs of both the models
are plotted and shown clearly in this paper. As shown in
fig.2 and fig.5, the efficiencies of both the models at rated
speed 1000 rpm are 93%. The efficiency is calculated in
RMxprt which neglect few losses and hence the practical
design will have efficiency of nearly 90%, still it is very
high efficiency for this application.
Similarly, based on fig.4 and fig.7, the output torque
characteristics have an inverse relationship with the speed.
Comparative analysis, as shown in Table 5 determines the
difference in the readings of the two designed models based on
some crucial parameters such as rated voltage, average input
current, stator slot fill factor, efficiency, saturation, etc. This is
an In-Wheel motor that can be used in high-speed bikes and
bikes to provide the necessary traction required in them.
6

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