Love essays. Proper things for putting down thoughts.
Recommendations? Yohoo! Essay time!
First the disclaimer. I am not an expert. I do not know it all, and am always willing to learn something new. I do have strong opinions on just about anything so if you ask, be prepared for an answer you may not agree with.
LEe: Opinions lesser gods but data better. I know I know little because of what I know I know and what I suspect I still know.
OK, since you said budget build, I will assume you are talking about the cheapest DIY system that meets your requirements of around 12KW and 48V.
I'm going to recommend the Thunderstruck ME1616 motor with the Thunderstruck 12-24KW Gear Reduction set from
Thunderstruck-ev.com. But for a controller I would recommend an EZkontrol Motor controller from Goldenmoter.bike. Both sites have cooling water components. All in this is going to set you back $4-5k US$ (or more).
Lee: Water cooling is an absolute must have at this power. You cannot get enough cooling any other way.
If you had said easiest, for your 40' boat, for $10k I would go with the Electric yacht QuietTorque 15.0 LC Electric Motor (the LC apparently means liquid cooled). I think it uses the same motor and comes with almost everything; a throttle, display, and output shaft mounted water pump.
For either of the above I would recommend a fresh water closed loop cooling system, for that you will also need to get a radiator with fan, or a heat exchanger with separate raw water pump.
Lee: closed loop may long term be more serviceable in marine environment.
Now for the why.
The ME1616 is a water cooled PMAC motor that uses sinusoidal wave form control, which is quieter than a BLDC motor that uses square (or trapezoidal) wave form control. I can run at 550 Amps for 1 minute (28kW at 51.2V) and 250 Amps continuous (12.8kW at 51.2V)
Water cooling is important for just about any boat application. The controller will overheat way before the motor.
The controller I recommended is a water cooled version and while you can not change the voltage, you can change practically every other setting on it. And you can set it to run sine wave or square wave motors. For your boat I recommend the EZ482000, It is capable of 1000 Amps (2000 is the phase amps). It is 4" longer than the EZ481200 (600Amps) and it will run cooler at any Amp rate you run it. And it's only about $200 more, so my thinking is spend the extra and only buy it once.
The gear reduction unit uses a 1" cog belt and pulleys that can be bought many places to change the gear ratio if needed, for your boat I would recommend getting the largest ratio to start with.
Lee: Cog belt or dual cog belts are very reliable, efficient and can be easily replaced. Spares are not expensive and light and have good shelf life.
If I were in your shoes I would go with the Electric yachts QuietTorque 15.0 LC.
Yes it's double the money (but still way cheaper than a comparable diesel) and saves so much headache it's not even funny. And it has a 3 year warranty.
And no, I am not affiliated with, work for, or get commissions from ANY companies or web sites mentioned above (or anywhere else, I don't work in the EV or marine industry).
Lee: Good recommendations but for me definitely note economical. This industry is bleeding edge still and can charge a lot. The guys at Sailing Uma recommend another brand that adds generation. If you are off shore sailing generation seems to be a mandatory requirement.
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