Design and assembling of a permanent magnet synchronous machine with a Halbach magnet array for the application in an electric driven race car

The paper discusses design and manufacturing of a prototype permanent magnet synchronous machine for an application in a fully electric driven racing car. Very high performance and low mass of these machines are achieved by using high performance FeCo stator sheets, a fractional slot stator winding build of tooth coils as well as a Halbach magnet array with a novel segmentation technology for reducing the eddy currents. The final design of these 40 kW / 30 Nm machines yields a total mass of only 3.95 kg. The operating range is up to 18000 rpm with a nominal speed of 12600 rpm.