Electric drive concept for future vehicles: hub motor

In order for electric vehicles to become part of everyday life, new vehicle designs and components are needed. Taking the hub motor as an example, one of the advantages of the hub motor is that it can be installed directly in the wheel without the need of a conventional engine room, which provides the designer with more choices in vehicle design. Since the transmission is omitted, energy loss and mechanical wear during mechanical transmission are reduced. In addition, direct drive of the wheel improves drive dynamics and driving safety.

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The earliest invention of the wheel motor dates back to the 19th century, and the 1900 Paris World Expo once exhibited the "Lohner Porsche" car equipped with this motor from Ferdinand Porsche. The Fraunhofer Institute for Manufacturing Engineering and Applied Materials (IFAM) says they are developing a new hub motor that integrates all the necessary electrical and electronic components, especially power electronic control systems. Therefore, the number and range of external electronic components and feeders of the motor can be minimized. Compared with the hub motors currently on the market, this new motor will be significantly improved in terms of kinetic energy. In addition, it has an innovative safety and redundancy design concept to ensure safe driving. In addition to IFAM, researchers at the Fraunhofer Institute for Integrated Systems and Equipment Technology (IISB), the Institute of Materials Mechanics (IWM), and the Institute for Structural Durability and System Reliability (LBF) are studying these issues.

In response to criticism from critics of the negative impact of hub motors on vehicle handling, Dr. Hermann Pleteit, IFM project manager, responded that the engine is very compact. The high power and torque density only slightly increase the unsprung mass, but by configuring the chassis (such as the muffler setting), these effects can be effectively compensated without affecting the comfort of driving.

Researchers also face another challenge: compared to traditional cars, electric vehicles can recover the energy from the braking process and re-storage it into the battery. Now they are studying how to maximize this energy recovery. The traditional brake system will continue to be used, but it will only be used in an emergency.

Researchers at the Fraunhofer Institute in Germany are not only researching individual components, but also developing the entire car body. They integrated these components into a concept car called "Frecc0" as a scientific test platform. From next year, automakers and suppliers can also test new components with "Frecc0". This model is based on the Artega GT concept car. The establishment of this test platform and the design of the hub motor process are two of the "Fraunhofer Electric System Research" projects. The main topics of Fraunhofer's electric system research include automotive design, energy production, distribution and use, energy storage technology, system integration technology and social and political issues. The German Federal Ministry of Education and Research (BMBF) provided Fraunhofer with funding of 44 million euros, with the goal of developing prototypes of hybrid and electric vehicles to support the development of the German electric vehicle industry.

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