The design of an in-wheel electric motor for the solar-powered vehicle ‘Aurora’, entered in the 1996, 3010 km Darwin – Adelaide World Solar Challenge solar car race is described. Compared to other entrants in the race, the brushless DC motor is more efficient (97.5% compared to 92–95%) and lighter (8.3 kg compared to 12–16 kg) than all other direct-drive motors, and more efficient than all motor/gear combinations. This is achieved by the use of high flux-density rare-earth magnets, and computer aided optimisation of an axial-flux configuration consisting of a Halbach magnet array and an ironless air-gap winding.
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