We developed an ultra-thin DC brushless motor for use as the auxiliary drive of the ultra-low-fuel-consumption hybrid car, “INSIGHT”.Use of an ultra-thin design for this motor overcomes restrictions of the layout construction between the engine and the transmission. The ultra-thin design was achieved using a concentrated winding for the salient-pole of the split stator and a centralized distribution bus ring. Utilization of these technologies resulted in a maximum output performance of 10 kW at a maximum torque of 83.3 N-m while keeping the width of the electromagnetic motor circuits to a mere 60 mm. In addition, since the use of this arrangement for the motor subjects it to the effects of water and dirt just as with the clutch compartment, a joint chamber and labyrinth construction is used to form a drain. Meanwhile a stator cover and disk sensor are employed to prevent foreign matter from entering. This design achieves a motor capable of withstanding a harsh ambient environment.
Article of Honda R&D Technical Review Vol.12 No.1 (15 - 20)