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Status
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Released
Reviewed
Project title:
Article number:

01
Draft
497686
11L8 E-Motor

Michael Veeh
Requirement Specification
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1 Index
1 Index.............................................................................................................................................. 2
Preamble............................................................................................................................................... 4
Overview............................................................................................................................................... 4
1.1 KTM...................................................................................................................................... 4
1.2 Baumüller.............................................................................................................................. 4
1.3 Change history of the requirement specification versions.....................................................4
2 General Projekt Guidelines.......................................................................................................... 5
2.1 Development Scope Abstract............................................................................................... 5
2.2 Objective and Classification of the Component....................................................................5
2.3 Execution Regulations.......................................................................................................... 5
2.4 Development, Supply and Quotation Scope.........................................................................5
2.5 Properties, Conditions and Durablility...................................................................................5
2.6 Development Process........................................................................................................... 6
2.6.1 Schedule and Milestones......................................................................................... 6
2.6.2 Prototype Statuses................................................................................................... 6
2.6.3 Prototype Quantities................................................................................................. 7
2.6.4 Acceptance Procedure............................................................................................. 7
2.6.5 Type Approval and Certification...............................................................................7
2.7 Quality and Reliability........................................................................................................... 7
2.7.1 Quality Concepts...................................................................................................... 7
2.7.2 Risk Management.................................................................................................... 7
3 Project Management..................................................................................................................... 8
3.1 Project Management and Organization................................................................................8
3.2 Documentation...................................................................................................................... 8
3.2.1 Hardware Documentation........................................................................................ 8
3.3 General Documentation........................................................................................................ 8
3.4 Logistics Requirements......................................................................................................... 8
4 System Environment.................................................................................................................... 9
4.1 Functional System Environment........................................................................................... 9
4.2 Physical System Environment.............................................................................................. 9
4.3 System Circuit Diagram...................................................................................................... 10
5 Technical Requirements............................................................................................................ 10
5.1 Naming and Part ID No....................................................................................................... 10
5.2 Block and Principal Diagram...............................................................................................10
5.3 Functions............................................................................................................................ 11
5.3.1 Functional Description............................................................................................11
5.3.2 Service and Application Functions.........................................................................12
5.4 Architecture......................................................................................................................... 12
5.5 Electrical Interfaces............................................................................................................ 12
5.5.1 Connector and Pin Assignment..............................................................................12
5.6 Safety Requirements.......................................................................................................... 13
5.6.1 Person and Passenger Protection and Vehicle Safety...........................................13
5.6.2 Fire prevention....................................................................................................... 13
5.6.3 Functional Safety................................................................................................... 13
5.6.4 Safety Goals........................................................................................................... 13
5.7 Weight Targets................................................................................................................... 13
5.8 Installation........................................................................................................................... 13

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5.8.1 Installation Location............................................................................................... 13

5.8.2 Assembly Concept and Requirements form Production.........................................13
5.8.3 Geometry and Tolerances......................................................................................13
5.9 Styling and Design.............................................................................................................. 14
5.9.1 Cooling................................................................................................................... 14
5.10 Ergonomics......................................................................................................................... 14
5.10.1 Optical Characteristics, Surface and Handling.......................................................14
5.10.2 Acoustics................................................................................................................ 14
5.10.3 Technical cleanliness............................................................................................. 14
5.11 Technical Material Requirements.......................................................................................14
5.12 Resistance to Media and Chemical Requirements.............................................................15
5.12.1 Contamination........................................................................................................ 15
5.12.2 Cleaning................................................................................................................. 15
5.12.3 Protection Classes................................................................................................. 15
5.13 Enviromental Compatibility................................................................................................. 15
5.13.1 Material Selection................................................................................................... 15
5.13.2 Recycling Scheme.................................................................................................15
5.13.3 Recycling Rate....................................................................................................... 15
5.14 Mechanical Requirements.................................................................................................. 15
5.14.1 Loads..................................................................................................................... 15
5.14.2 Mechanical Interfaces...........................................................................................15
5.14.3 Vibration Generation Behavior................................................................................16
5.14.4 Additional Mechanical Requirements.....................................................................16
5.15 Endurance.......................................................................................................................... 16
5.16 Electric Requirements......................................................................................................... 17
5.16.1 General requirements............................................................................................17
5.16.2 Electrical energy efficiency.....................................................................................17
5.16.3 Measurement accuracy..........................................................................................17
5.16.4 Electrical operating conditions................................................................................17
5.16.5 Electromagnetic compatibility (part of KTM)...........................................................17
5.17 Climatic Requirement......................................................................................................... 17
5.17.1 Climatic operating conditions.................................................................................17
5.18 Service Requirements (must be defined between KTM and BM).......................................18
5.19 Transport Protection (must be defined between KTM and BM)..........................................18
5.20 Quality Assurance Requirements.......................................................................................18
6 Testing and Validation................................................................................................................ 18
6.1 Test Equipment and Test Mules......................................................................................... 18
6.2 Testing Plan........................................................................................................................ 18
6.3 Test specification requirements.......................................................................................... 18
6.4 Vehicle Testing................................................................................................................... 19
6.5 Virtual Testing and Simulation............................................................................................19
7 Definitions, Terms, Acronyms................................................................................................... 20
8 Further Applicable Documents.................................................................................................. 22
8.1 Normative references......................................................................................................... 22
8.2 KTM Standards................................................................................................................... 22
8.3 Project Specific Documents (to be define)..........................................................................22

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Preamble
KTM designed an electrical motor 11L8 for a motorbike with about 11 KW power as a A-Sample status. The
basic construction and the geometrically dimensions were fixed by KTM.

Baumueller has the task to develop this A-Sample to a ready to go serial production with professional quality,
optimized performance ratings and a cost optimized solution.

The goal of KTM and Baumueller for the motor is to create a symbiosis between performance, quality and
cost optimization.

Therefore there will be an ongoing process until the C3 samples status to fulfill these requirements.
The definition “shall” is therefore the goal for both sides. (goal*)

Overview

1.1 KTM
Company: KTM Forschungs & Entwicklungs GmbH
Street: Stallhofnerstraße 3
City: 5230 Mattighofen
County: Austria
Project leader: Mr. Bharat Singh

1.2 Baumüller
Company: Baumüller Nürnberg GmbH
Street: Ostendstr. 80
City: 90482 Nürnberg
Country: Germany
Projektleiter: Mr. Gerhard Stempfle

1.3 Change history of the requirement specification versions

Version Date Name Type of change Status
0.1 27.03.2023 Veeh Michael Creation of the requirement specification Draft

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2 General Projekt Guidelines

2.1 Development Scope Abstract

A. The function of the PMSM is to convert the AC electrical power supplied by the MDU into mechanical
shaft power to provide drive torque for the vehicle as mentioned in the requirement specification
document.
B. This requirements specification consists of technical requirements for the development of a 3-phase,
6-pole (3 pole-pair) permanent magnet synchronous machine (PMSM) for a two- wheeler, operated
at 50.4V DC (nominal), in which the specification will be detailed and fixed during the C-sample
stage.
C. KTM developed concept shall be used as a reference point for the project and relevant changes
shall be proposed and agreed on with KTM to be able to industrialize the E Motor and meet the
requirements as presented in the document.
D. KTM proposed concept is as attached, See the “Motor Concept” referred in chapter 8.3. C.
E. The PMSM shall have the following interfaces to the system:
a. vehicle harness for motor temperature and RPS system
b. cooling system
c. lubricating system
d. geometrical interface / packaging
e. sealing interfaces
f. connection terminals

2.2 Objective and Classification of the Component

A. The target market for the product at release is defined in chapter 8.3. J.
B. The PMSM shall comply with all the statutory and regulatory requirements that apply for the intended
sales target markets at the time of the type of approval test.
C. Legal requirements that come into operation during the product development shall be implemented
immediately.
D. The development shall be always optimized with regards to the following aspects: degree of
efficiency, service life, costs, weight, geometrical dimensions until the C-sample status.

2.3 Execution Regulations

All existing arrangements and agreements between KTM and Baumueller retain their effectiveness (e.g.
confidentiality agreement).

2.4 Development, Supply and Quotation Scope

A. Baumueller shall supply KTM with all prototypes defined in this document.
B. Baumueller shall draw up following costs separately:
a. Development costs
b. Prototype costs
c. Costs for serial parts
d. Validation and qualification cost
e. Certification and approval cost
f. Tooling investment cost
g. Hourly or daily engineer cost at an external partner, if applicable

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2.5 Properties, Conditions and Durablility

A. Baumueller shall design the components to a reliable, robust state of the art design to achieve the
durability under the defined environmental and operating conditions.
B. Minimum shelf-life rating for the component shall be 10 years. NOTE: The service life starts when
the goods are received by KTM. Storage conditions must be define.
C. The minimum full functional capability shall be ensured for 1750 operating hours and 10 years on
general maintenance regime without any replacement of parts. Storage not allowed with bike not
moving more than 2 years. Special requirements have to define in Req. Spec / Manual.
D. Duration for spare parts availability is agreed within the “Purchasing Conditions” and have to be
regulated in detail separately.

2.6 Development Process

2.6.1 Schedule and Milestones

2.6.1.1 Schedule

A. The schedule shall be according the “KTM project plan” referred in chapter 8.3. A
B. Baumueller shall provide a project plan with all relevant tasks and milestones.

2.6.1.2 Milestones

A. A-samples: week 32 2021

B. B1-samples: week 47 2021
C. B3-samples: week 21 2022
D. C-samples: week 02 2024
E. Pre series (D-samples) week 20 2024
F. Series production: week 26 2024
G. Valid for the milestones is the actual “KTM project plan” referred in chapter 8.3. A

2.6.1.3 Reviews
The following documents and information shall be disclosed and - when required - made available for KTM:

a. List of tools used during the development process

b. Documentation of process, material and parts used for the prototypes
c. Schematics and layout

2.6.2 Prototype Statuses

2.6.2.1 A-Samples

A. The functional requirements according to chapter 5 should be implemented in the A-Sample stage.
All deviations (not implemented functions) shall be expressed in a deviation list. For this project a
deviation list shall be generated and shared with KTM. Done by KTM.
B. Performance tests should be done in the A-Sample stage.
C. No endurance test should be done in the A-Sample stage.
D. No serial tooling and production infrastructure is required to produce the A-Sample stage.
E. The A-Sample stage could be integrated at KTM in P0 or P1 vehicle stage.

2.6.2.2 B-Samples

A. All functional requirements according to chapter 5 shall be implemented in the B-Sample stage. All
deviation shall be expressed in a deviation list. For this project the deviation list shall be generated
and shared with KTM.

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B. Parts of endurance and validation testing according to chapter 6 will be done in the B- Sample stage
and have to discuss and agree between KTM and BM.
C. No serial tooling and production infrastructure is required to produce the B-Sample stage.
D. The B-Sample stage could be integrated at KTM in P1 or P2 vehicle stage.

2.6.2.3 C-Samples

A. All functional requirements according to chapter 5 shall be implemented in the C-Sample stage.
B. All endurance and validation testing according to chapter 6 will be done in the C-Sample
stage.
C. All environmental requirements according to chapter 5 shall be implemented in C-Sample stage
D. Serial production tooling shall be used to produce the C-Sample stage.
E. Serial production infrastructure should be used to produce the C-Sample stage.
F. The C-Sample stage could be integrated at KTM in P3, sample production or pre-production
vehicle stage.

2.6.2.4 D-Sample (Part-Submission-Warrant-Parts)

A. All functional requirements shall be implemented in the D-Sample parts.

B. Mass production and serial production infrastructure shall be used to produce the D-Sample parts.
C. Full documentation as required in chapter 3.2 shall be provided by Baumueller together with the D-
Sample parts.
D. Provide PPAP level 3 documents (TBD) to [email protected].

2.6.3 Prototype Quantities

A. Prototype Quantities will be aligned between Baumueller and KTM Purchasing Department.

2.6.4 Acceptance Procedure

A. After the testing period for the B-Samples a technical release for design and performance will be
given in writing by KTM R&D department. This is a technical release for the production/delivery of
the C-Samples.
B. After the testing period for the C-Samples a technical release will be given in writing by KTM R&D
department and a release of product drawing will be provided by KTM purchase department. This is
a technical release for the production/delivery of the D-Samples.
C. After the delivery and the testing of the D-Samples a technical release will be given in writing by KTM
R&D department and quality management department and a release of product drawing will be
provided by KTM purchase department. This is a technical release for the serial production and the
release for the delivery of the serial production parts.

2.6.5 Type Approval and Certification

A. Baumueller shall deliver a declaration of conformity for the component

B. The component shall have a certification according to applicable CE standards.

C. The component shall have a certification according to applicable UL standards.
D. CE and UL is topic from KTM. Baumueller can only deliver the PMSM prepared for CE and UL
(incomplete machine).

2.7 Quality and Reliability

2.7.1 Quality Concepts

Please refer to the KTM Standard Quality Assurance Agreement (QSVSTD-ELECTROMOTOR) for the
general quality concepts of the project.

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2.7.2 Risk Management

In order to estimate the risks during development, testing and production phases of the components
specified in this document:
a. Baumueller shall provide a System Failure Mode and Effects Analysis on component level.
b. Baumueller shall provide a Product- and Process – FMEA according to the document VDA
Volume 4.
c. FMEA must be updated to the latest version.

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3 Project Management

3.1 Project Management and Organization

Baumueller shall nominate for this project following responsible persons:
a. Project Manager
b. Sales Manager
c. Quality Manager
d. Functional Safety Manager

3.2 Documentation

3.2.1 Hardware Documentation

A. Baumueller shall deliver a technical hardware specification with following content:

a. Description of the HW architecture, design, and appropriate block diagrams.

b. Environmental operating conditions
c. Operating temperature range. Refer to chapter 5.3.1 D for details
d. Detailed input and/or output specification and functional description of all interfaces (e.g.
min/max. currents, voltages etc.) and appropriate block diagrams (e.g. input schematics) in
Baumueller data sheet.
e. Detailed HW test and validation specification (e.g. performed durability test, testing
conditions etc.).
f. Detailed documentation of all performed testing of prototype stages and serial production
parts.
g. Assembly instructions for the PMSM is scope of delivery from Baumueller and shall to be
enclosed in the motorbike.
h. Product drawings

B. The supplier shall deliver a product drawing according to the document “Suppliers Drawing Content”
referred in chapter 8.3. O.
C. Baumueller shall deliver 3-D data of the component in *.stp or *.step format.
D. The supplier shall deliver a DFMEA for the component. The template is shared in chapter 8.3. T.

3.2.2 Conformity Requirements

A. Please refer to chapter 2.6.5 for the conformity requirements.

3.3 General Documentation

A. Baumueller shall deliver a product requirement specification (for parts not based on drawings in form
of drawings or data sheets)for the configuration of the prototypes and for the serial production parts.
B. Baumueller shall deliver all documents as required in the KTM Standard Quality Assurance
Agreement (QSVSTD-ELECTROMOTOR) referred in chapter 8.2. B.
C. The supplier shall deliver the documentation as agreed together with the supplier in the
Development Interface Agreement (DIA).

D. The supplier shall deliver the documentation for assembly instruction.

3.4 Logistics Requirements

A. The packaging of the components shall be according to the document “Packaging Specification for
suppliers” referred in chapter 8.2 C. and have to define between KTM and Baumueller.
B. Packing Material will be provided by KTM.

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4 System Environment

4.1 Functional System Environment

A. [Note] Figure 1 serves as an information about the system architecture
B. System-level input required for the development of the PMSM and not known to Baumueller shall be
requested by Baumueller. Changes to be provided by KTM.

Figure 1

4.2 Physical System Environment

A. The PMSM shall be a part of a two wheeled vehicle Electric drivetrain, the PMSM will cater for a
broad range of electric two wheelers.
B. The PMSM shall be powered by the MDU (operating at 50.4 Vnominal DC) with a 3-phase AC
supply of around 35.6VRMS (nominal voltage). Specifications will be detailed and fixed during the C-
sample stage.
C. The voltage range is staggered as following by the MDU (only informative view):

Figure 2
D. [Note]: The maximum battery voltage is 58.8 V DC.
E. The PMSM shall incorporate an analog position sensor (‘Rotor Position Sensor’) which will be
designed by KTM, see attached documentation in chapter 8.3. D-F
F. Baumueller shall implement the RPS according to the provided documentation in 4.2. E and the
limitations specified therein.
G. The Rotor Position Sensor shall be powered by the MDU.

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H. A temperature sensor system shall be installed in the PMSM to allow the MDU to monitor the motor
temperature and to trigger derating / cut-offs for the safe operation of the PMSM
within its operational limits.
I. [Note]: Baumueller has identified phase V, slot 11 on the non-drive side, end of the stator
as the a hotspot. Baumueller has chosen one PT1000 sensor to be placed at this position to
fulfill 4.2. G.
J. The temperature sensor system shall be connected directly to the RPS board via the
connector specified by KTM and confirmed for use by Baumueller. The temperature sensor
system will be powered by the MDU.
K. A single cable shall be then directed from the RPS to the MDU.
L. The single combined cable (RPS Cable) shall interface with a connector specified by KTM
and confirmed for use by Baumueller. See Chapter 5.14.2.2. for detailed information.
M. The power line connection shall be facilitated through three separate terminals, each
dedicated to the separate phases U/V/W. They shall be electrically isolated and provide an
external M6 thread each to mount three separate power lines to them. See Chapter
5.14.2.3. for detailed information.
N. The PMSM design shall be water-cooled. The cooling system shall interface with a housing, part of
the cooling system.

O. The dimensions of this housing will be shared by KTM, Baumueller and KTM shall guarantee full

intended functionality and a cooling-medium tight seal to this housing. See Chapter 5.14.2.1.

for detailed information. KTM is responsible for the tightness of the system.

P. The drive-side of the PMSM (A-sided bearing) is exposed to a gearbox, to which the gear on

the shaft shall interface. The internals of the PMSM and the cooling circuit shall be

effectively sealed off from the oil circulating in the gearbox. KTM is responsible for the tightness of
the system.

Q. The PMSM will not be sealed on the interface plane with the drive unit to the exterior, it shall be
designed to effectively uphold the IP67 / IP6k9k rating in this mounting condition. KTM is responsible
for the tightness of the system.

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4.3 System Circuit Diagram

A. TBD

5 Technical Requirements

5.1 Naming and Part ID No.

A. The component shall have the part number: T200.47.000.000
B. The component shall be labeled in accordance with the document “General regulations for labelling
of EE-parts” referred in chapter 8.2. D.
C. There shall not be any visible Baumueller logo for the end user. Final agreement to be documented
in chapter 8.3. S

5.2 Block and Principal Diagram

Figure 1 shows functional schematic representation of the PMSM.

Figure 3

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5.3 Functions

5.3.1 Functional Description

A. The performance requirements for the PMSM are mentioned in the chapter 5.3.1.4
B. The PMSM shall convert power between electrical AC power and mechanical shaft power.
C. The PMSM shall be capable of performing its primary power conversion function in all four quadrants
of the speed/power chart.
D. The PMSM shall have a BackEMF voltage constant of 2,3548 V/1000rpm per phase with a tolerance
of +/- 5%. Specifications will be detailed and fixed during the C-sample stage.
E. The PMSM shall be able to sustain a mechanical power output of at least 1110,4 kW continuous.
Specifications will be detailed and fixed during the C-sample stage.
F. [Note]: Continuous is defined through the S2 30 min specification for this use case.
The following conditions are to be considered:
G. The PMSM shall provide winding temperature information to the MDU at non drive end winding
position. The exact position and evaluation of the position shall be provided by Baumueller during
the C-sample stage.
a. Baumueller shall define a “power reduction temperature”, at which the vehicle control unit
should reduce the maximum available power.
b. Baumueller shall define a “cutoff temperature”, above which the vehicle control unit should
not demand power output from the PMSM.
c. Between the “power reduction temperature” and the “cutoff temperature” a linear reduction of
the maximum available power will be conducted by the vehicle control unit. This may be
subject to change
d. The “power reduction temperature” and the “cutoff temperature” reference the values
provided by the PT1000 temperature sensor installed at the position provided by Baumueller.
e. The evaluation of the position shall be supported by a hotspot-simulation of the
winding and a thermal calculation of the motor to eliminate the possibility of performance
decreasing effects (e.g., rotor demagnetization).

5.3.1.1 Functional States

[Note]: The PMSM is not expected to have any integrated ECU nor any associated functional state machine
except for the RPS.

5.3.1.2 Self-Protection Functionalities (not inside the motor)

A. The bearings would be designed/specified in a way that the PMSM does not incur any performance
degradation over the mentioned time/span life. Will be define after long time test by Baumueller.
B. The PMSM shall sustain the mechanical loads transmitted through the drive unit which are provided
exemplary in the load collective (status march 2022), as described in chapter 8.3 K. Specifications will
be detailed and fixed during the C-sample stage.
C. [Note]: Load collective may be subject to updates over the sample stages
D. The design of the PMSM, especially the bearing shield and back cover, shall take care to avoid
interference on the communication, control or signal lines.
E. The internals (windings, magnets, bearings etc.) shall be ensure to sustain the requested
performance as defined in chapter 5.3.1.4. Result of type test is necessary
F. The magnets shall be designed / specified in a way that the PMSM does not incur any performance
degradation over the mentioned lifetime and does not experience any demagnetization.

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5.3.1.3 Input / Output Protection

A. Each motor phase shall be protected against shorting to another motor phase, relevant separation
process shall be applied. The suitable process and insulation resistance shall be defined by
Baumueller.
B. Each motor phase shall be protected against shorting to the motor casing, the terminals shall not be
accessible directly, an additional part included in the design to meet this requirement could be
considered but shall be discussed with KTM. The suitable process and insulation resistance shall be
defined by Baumueller. Will be detailed and fixed during the C-sample stage.
C. In case the phase connection-points come in contact with water, it shall be guaranteed that the water
can dissipate completely. Will be detailed and fixed during the C-sample stage.
D. All input- and output signals shall be sufficiently protected from EMC / EMI interference caused by
the motor operation. EMC/EMI caused by unprotected cable is under responsibility by KTM. KTM is
responsible for the system.

5.3.1.4 Performance Characteristics

A. Rotational speed of the PMSM under full load of the MDU shall be 11 000 RPM minimum.
B. Rotational speed of the PMSM under no additional load created by the MDU shall be 14 000 RPM
minimum
C. Efficiency of the PMSM shall exceed the map presented in Figure 4 under the following conditions:
a. DC Voltage supply: 50,4 V
b. DC current supply: 450 A
c. Ambient temperature: 25°C
d. winding temperature: 70°C

Figure 4: Minimum allowed efficiency map of motor

D. Max torque rating of the PMSM shall exceed 37Nm from 0 rpm to 4700 rpm.
E. The PMSM Continuous power capability (S2 duty cycle rated for 1800 seconds according to ISO
60034-1) shall exceed 11 kW shaft power at 6500 rpm under the following environmental conditions:
a. DC Voltage supply: 50,4 V
b. DC current supply: 2530 A
c. Ambient temperature: 25°C
d. Coolant Inlet temperature: 70°C
e. Airflow: 54 km/h (correlating vehicle speed to rpm)
f. Coolant flow rate: 8 l/min
g. Pressure drop over cooling jacket: 220 mbar
F. The PMSM shall be capable of excursions beyond the S2 30 min duty cycle rating of at least 19.5 kW
shaft power for at least 30 seconds at 6000 rpm under the following environmental conditions:
a.DC Voltage supply: 50,4 V
b.DC current supply: 450 A
c. Ambient temperature: 25°C
d.Coolant Inlet temperature: 70°C
e.Airflow: 54 km/h (correlating vehicle speed to rpm)
f. Coolant flow rate: 8 l/min

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g. Pressure drop over cooling jacket: 220 mbar

G. The PMSM shall be capable of 12.3 kW shaft power for at least 30 seconds at 35V DC
voltage and more than 3000 rpm.

5.3.2 Service and Application Functions

The full envelope of replacement parts must be agreed between Baumueller and KTM

5.4 Architecture
KTM to share system architecture after A-sample testing.

5.5 Electrical Interfaces

5.5.1 Connector and Pin Assignment

A. Sensor connectors shall be designed to prevent the connection points from being connected in an
inappropriate way (poka yoke). This is defined with KTM. Connector for position sensor will be
specified by KTM with poka yoke.
B. The cross-sections of the stator windings and the connection box pins shall be chosen by the
Baumueller according to the electrical loads possible within the functional envelope of the PMSM
and shall be agreed with KTM. Will be detailed and fixed during the C-sample stage.

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5.6 Safety Requirements

5.6.1 Person and Passenger Protection and Vehicle Safety

A. The Encoder in the PMSM is a safety-relevant component. A corresponding design shall be
considered during the development. Baumueller needs therefore a definition of the safety level from
KTM that can be evaluated.
B. A mechanical model of the component shall be provided for the simulation purposes.
C. The PMSM shall be designed that no danger exists to persons in its environment during operation.
Cover for Connection box is defined by KTM and KTM is responsible for that.
D. The PMSM shall not catch fire. A fire due to an electrical failure of the component shall be
prevented.
E. The 3-phase short circuit torque of the machine shall be lower than 15Nm.
F. The 3-phase short circuit current of the machine shall be lower than 340 ARMS.

5.6.2 Fire prevention

The protection against the development and spread of fires shall be ensured and proven by Baumueller.

5.6.3 Functional Safety

Safety Targets TBD
C. The PMSM shall not expose the RPS to conditions beyond its limitations. The RPS is a ASIL
component and relevant integration measures shall be taken. TBD between KTM and
Baumueller.
D. The temperature monitoring system shall comply to a FIT rate below 5 FIT according to ISO
26262. Refer to chapter 8.3. R for the FIT rate calculation provided by Baumueller.

5.6.4 Safety Goals

A. Feeding overvoltage into the DC network shall be limited to 80V eff in an event of a short circuit by
the inverter or internal failure of the PMSM, the back EMF at 11000 RPM within the rotational speed
range up to the maximum no load RPM shall be limited appropriately.
B. [Note]: This Requirement does not overrule 5.3.1. D.
C. Spreading of thermal events, e.g., due to overcurrent or overvoltage on the DC side, shall be
prevented. TBD between KTM and Baumueller.

5.7 Weight Targets

The complete PMSM weight shall be less than 11 kg. Will be fixed during the C-sample stage.

5.8 Installation

5.8.1 Installation Location

The PMSM shall be installed in the vehicle drive unit with the provided interface, see drawing No. 13004251
B.

5.8.2 Assembly Concept and Requirements form Production

A. The assembly concept shall be agreed between KTM and Baumueller.
B. Mounting concept (screw holes, openings, etc.) shall be agreed between KTM and Baumueller. See
Baumueller drawing No. 12112524 C.
a. Simple change of PMSM shall be ensured.
b. During the assembly of the rotor position sensor (RPS) onto the PMSM, Baumueller shall
ensure that no damage, especially in the form or ESD, can occur until the RPS is sealed
within the PMSM

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c. All relevant sealing elements shall be mounted during the production process at Baumueller
and be protected from any damages or pollution until the assembly into the system at KTM
d. The interfacing holes for the two fitting pins placed on the drive unit shall provide a chamfer
of 1 x 45° for guidance during the insertion process

5.8.3 Geometry and Tolerances

A. The PMSM shall be designed for as little installation space as possible.
B. The maximum permitted design dimensions are as per current KTM concept. See Baumueller
drawing ….

5.9 Styling and Design

A. Plug connector and studs shall be located see Baumueller drawing no. … .
B. It shall be possible to lock/unlock and unplug all interfaces (e.g., signal-plugs, ground connection and
48V AC connection) in equipped state.
C. Locking and screw connections shall be designed for 20 de- and assembly operations through
lifetime for the power connection.
D. The correct snapping-in of plugs shall be able to be tested optically, acoustically or by pull- out test.
E. The PMSM shall not have any sharp edges that could potentially cause harm.

5.9.1 Cooling
A. The PMSM shall be designed to accommodate cooling by a BASF G48mix (50:50) – check by
Baumueller necessary.
B. The available coolant flowrate for the PMSM is 8 l/min (to be confirmed by KTM and Baumueller)
C. [Note]: This value references measurements conducted with the B-sample. It depends partly
on the pressure drop and might vary if the surface of the cooling channel deviates from the
B-sample.
D. The pressure drop at the rated flowrate is not to exceed 220 mbar at Tcoolant 65°C – to check by
Baumueller.
E. A torque de-rating is permitted to prevent further heating due to the electrical operation. A
corresponding strategy shall be developed using the simulation data and measured data and agreed
with KTM.
F. Power derating and cut off limit shall be provided by Baumueller.

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5.10 Ergonomics

5.10.1 Optical Characteristics, Surface and Handling

A. The optical and surface characteristic shall be according to the product drawings. See baumueller
drawing no.
B. Edges and corners which could negatively affect the ergonomics and further the safety or the
function shall be avoided.
C. The optical and surface characteristics shall be confirmed according to the QSV referred to in
chapter 8.2. E.

5.10.2 Acoustics
A. The PMSM shall achieve an A-weighted emitted sound pressure level defined by KTM and adjusted
with BM.
B. The PMSM shall not be subject to degradation of the acoustic performance over the lifetime of the
component

5.10.3 Technical cleanliness

A. Sufficient technical cleanliness shall be ensured for the PMSM’s own working, for the functioning of
other component parts and the functioning of sub-components.
B. Requirements for acceptable contamination as well as test procedures to prove the required
cleanliness shall be worked out and agreed with KTM have been drawn up based on VDA Band 19
C. Technical cleanliness tests shall be performed before the start of the series production. Results shall
be provided to KTM.
D. The PMSM shall be protected by packaging from damage and dirt during transport and storage.

5.11 Technical Material Requirements

A. Material concepts shall be selected to ensure compliance with the requirements of this specification
and agreed with KTM.
B. The material of wire connections shall be chosen to avoid corrosion over the whole lifetime.

5.12 Resistance to Media and Chemical Requirements

5.12.1 Contamination
A. The corrosion protection of PMSM shall ensure compliance with the corrosion resistance
requirements under the conditions imposed by the installation in the vehicle and the specified
climatic and mechanical loads and stresses (including dampness, salt, pelting, friction etc.).
B. The term "corrosion" is used to refer to all manifestations of corrosion defined in DIN EN ISO 8044.
C. Corrosions critical materials as basis material (zinc, magnesium, etc.) as well as different material-
pairings that leads to corrosions damage due to external influences are not permissible.
D. It shall be ensured that the PMSM and/or adjacent components do not sustain any damage caused
by chafing or accumulated water or dirt according to the IP class of the motor
E. The PMSM shall be resistant to the chemicals which are specified in the HWQ
F. Final verification of the corrosion resistance shall take place within the KTM vehicle testing.

The PMSM shall withstand all further contamination requirements defined in the document “HWQ Plan”
referred in chapter 8.3. L

5.12.2 Cleaning
A. The PMSM shall be suitable for high-pressure steam cleaning. Exact requirements must be define by
KTM and have to adjust with Baumueller.
B. The PMSM shall withstand all further cleaning requirements defined in the document “HWQ
Plan” referred in chapter 8.3. L
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5.12.3 Corrosion Protection

A. The corrosion protection of PMSM shall ensure compliance with the corrosion resistance
requirements under the conditions imposed by the installation in the vehicle and the
specified climatic and mechanical loads and stresses (including dampness, salt, pelting,
friction etc.).
B. The term "corrosion" is used to refer to all manifestations of corrosion defined in DIN EN
ISO 8044.
C. Corrosions critical materials as basis material (zinc, magnesium, etc.) as well as different
material-pairings that leads to corrosions damage due to external influences are not
permissible.
D. Materials shall not sustain any rust penetration and/or perforation within 12 years
E. The PMSM (with connected plugs) shall withstand the salt spray test according to IEC60068 2-52
without any functional consequence.
a. Severity level 4 (2 repetitions)
b. Functional status Not active
[Note]: A-E – to check by Baumueller
F. The PMSM shall withstand all further corrosion requirements defined in the document “HWQ Plan”
referred in chapter 8.3. L

5.12.4 Protection Classes

A. The PMSM (with connected plugs) shall have a minimum degree of protection according to
ISO20653 and IEC60529 of IP67 class except the drilling at the driveside of the housing.
B. Surfaces of PMSM (with connected plugs) which are accessible in the two-wheeler by a
pressure washer shall have a minimum degree of protection according to ISO20653 of IP
6K9K.
C. The PMSM shall withstand all further protection class requirements defined in the document
“HWQ Plan” referred in chapter 8.3. L

5.13 Enviromental Compatibility

5.13.1 Material Selection

A. For the material selection Baumueller should try to respect the Global Automotive Declarable
Substance List (GADSL).
B. The component shall satisfy the European Parliament and of the Council directive on the restriction
of the use of certain hazardous substances in electrical and electronic equipment (Restriction of
Hazardous Substances in Electrical and Electronic Equipment = RoHS).

5.13.2 Recycling Scheme

A. TBD

5.13.3 Recycling Rate

Baumueller should be able to calculate the recycling rate according to ISO22628:2002.

5.14 Mechanical Requirements

5.14.1 Loads
A. The mechanical loads shall be agreed with KTM.
B. The PMSM shall be fatigue endurable and able to sustain the loads transmitted through the drive unit
which are defined in the “Load Collective” (status march 2022) referred to in chapter 8.3. K.
C. The PMSM shall withstand all further mechanical requirements defined in the document “HWQ Plan”.

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5.14.2 Mechanical Interfaces

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5.14.2.1 Interface Driveunit

A. KTM specifies tolerance requirements for the interfaces between the motor and the drive unit.
B. The motor shall comply to the specified tolerances as agreed between KTM and Baumueller.
C. All tolerances shall be chosen so that the full functionality of the motor, the drive unit and the
complete system is guaranteed as agreed between KTM and Baumueller. The tolerances for all
interfaces to the cooling system shall be chosen so that full cooling system integrity is guaranteed as
agreed between KTM and Baumueller.
D. On the A-side of the motor, 4 holes for oil circulation shall be placed in order to guarantee required
lubrication of the A-sided bearing as agreed between KTM and Baumueller.
E. The holes shall be positioned in such a way that no part of the system is compromised
F. The 4 holes shall allow oil flow through the dedicated space between the A-sided bearing and the
radial seal placed on the shaft.
G. The diameter of each hole shall be 4 (3) mm and they shall be spaced evenly around the
circumference.
H. On the A-side of the motor a venting hole shall be placed to prevent a build-up of air pressure in the
motor and to allow circulation to a breather valve placed in the drive unit.
I. The drive unit will provide three sealing interfaces to the PMSM, the 3 contact surfaces
created through the external O-Rings. The PMSM shall handle all possible exposures
outside of these sealed perimeters.

All points in 5.14.2.1 must be agreed between KTM and BM and defined and approved in a drawing of the
engine.

5.14.2.2 Interface Position Sensor

A. The PMSM shall provide the mounting interface for the RPS compliant to the attached
documents referred to in chapter 8.3. D-F. The maximum allowed movement of the motor shaft in
relation to the RPS shall be limited to
the values specified in chapter 8.3. D
C. [Note]: Radial and axial play can be interchanged according to chapter 8.3. D.
D. The RPS shall not be exposed to operational temperatures outside the specified range in
chapter 8.3. F.
[Note]: A-D – to check by Baumueller

5.14.2.3 Interface Connection Box

A. The connection box shall offer an interface area for mounting of a 3 phase U/V/W the electric power
transfer from the MDU, a phase collector and a protective cover on the outside of the motor.
B. The phase collector and the protective cover will be supplied by KTM, the connection box interface
shall comply to the interface requirements agreed between KTM and Baumueller.
C. The connection pins shall provide three separate screw terminals for the individual phases
in the form of M6 threads.
D. The minimum allowable tightening torque shall be 10,1 Nm (±1,1 Nm) for each external
screw connection.
E. The minimum available thread length for the connecting screws shall be 15 mm.
F. The minimum permissible force transmitted to the connection pins shall be 310 N per
connection pin. Must be validated in test by Baumueller or by the supplier.
G. KTM has established that an external connection, without additional sealing elements, will
be utilized for the power lines. Baumueller shall design the interface accordingly.

5.14.3 Interface RPS Cable

A. Baumueller shall equip the PMSM with a cable that exits from the bearing shield of the

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PMSM. It shall transfer in- and output signals between the RPS and the vehicle wiring
Harness.
B. The exit position from the bearing shield is defined by KTM in agreement with Baumueller.
C. [Note]: the exit location was fixed to the position utilised in the B-sample stage of the PMSM.
D. All requirements, especially the sealing requirements extend to this cable also. KTM has decided this
cable is without shielding.
E. [Note]: Baumueller and KTM have concluded, that a rubber gromet around the base cable
should be used to comply to the sealing requirements. This gromet is referred to as part of
the RPS cable
F. Full functionality of the sealing, the cable and the complete PMSM shall remain intact,
including all specified water- and weatherproofing classes over the lifetime of the PMSM,
namely IP67 and IP6K9K.
G. The sensor cable assembly mounted in the the bearing shield with cover the screwed on it shall
withstand a minimum pull out-force of 100N in all possible axes out of the exit location of the bearing
shield, an additional strain relief inside the bearing shield may be used to accomplish this.
H. The RPS cable shall have the following connections: The following names must be assigned to the
type in the pinout by KTM: Signal of temperature sensor, Buffered sine channel, positive output,
Buffered cosine channel, positive output, Supply common ground, Supply voltage.
RPS side: Molex DuraClik; SN: 5023510701

Table 1: Pinout RPS connector

a. Vehicle side: Yazaki KE; SN: 7282-8850-30

Table 2: Pinout vehicle connector

I. The RPS cable shall consist of minimum five individual strands, each with a cross section of
0,35mm².
J. The length of the cable external of the motor shall be 115 mm tolerance ± 5mm, measured from the
middle of the RPS cable exit on the PMSM surface.
K. The geometry of the RPS cable shall protrude less than 23 mm from the outer surface of the
bearing shield.
L. The RPS cable shall be able to face axially in relation to the shaft after exiting radially out of the
bearing shield, parallel to the surface of the drive unit, towards the A-side of the PMSM.
M. The RPS cable, consisting of the specified connectors on both sides, the strands with
sheathing and the gromet, shall be interchangeable in case of failure.
N. KTM shall be allowed to route the RPS cable as per the packaging requirements of
individual projects within the allowed bending radius of the RPS cable.

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O. The allowed bending radius of the RPS cable shall be below 36 mm.

5.14.4 Interface Gearbox

A. The PMSM shall interface with the gearbox of the vehicle and transfer rotational mechanical
power between the rotor shaft and the interfacing gear on the drive unit.
B. The interface shall comply to the gearing calculation report provided by KTM, see chapter
8.3. M.
C. The transmittable loads shall comply to the load collective provided by KTM, see chapter
8.3. K

5.14.5 Vibration Generation Behavior

A. The rotational assembly of the PMSM shall achieve a balancing grade of G 2,5 in
compliance with DIN ISO 21940 – to check by Baumueller.
B. The PMSM shall limit all generated vibration to below an amplitude of 2,3 mm/s rms in compliance
with DIN ISO 20816 – to check by Baumueller.
C. The limits shall be agreed between KTM and Baumueller after the C-sample stage

5.14.6 Additional Mechanical Requirements

A. All additional mechanical requirements defined in the document “HWQ Plan” referred in
chapter 8.3. L shall be complied to.

5.15 Endurance
The minimum cycle life (product under normal operation condition) in the vehicle shall be 1750h.

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5.16 Electric Requirements

5.16.1 General requirements

A. The PMSM is classified as a High-Voltage device (Voltage Class B)
B. The PMSM total leakage current to chassis shall be <0.1µA.
C. The PMSM output voltage shall not exceed 100 V RMS when operated open circuit at maximum rated
overspeed.
D. The PMSM shall have a low (<5%) Total Harmonic Distortion (THD) when operating in generator
mode.
E. The PMSM non-drive-end bearings and rotor shall be prevented from damage caused by electric
current electromagnetically induced on the rotor arcing across the bearings.
F. The PMSM shall be rated for class H operation (including the windings, slot insulation material, and
wherever relevant)
G. Baumueller shall determine the correct wire grade to support full operational envelope of the PMSM
as mentioned in this document

Point 15.16.1 in sum will be detailed and fixed during the C-sample stage

5.16.2 Electrical energy efficiency

A. The degree of efficiency shall be better than 84% at 8000 rpm / 7 Nm.
B. Baumueller shall provide a degree of efficiency characteristic map over the entire torque- speed map
once per type from C-Sample based on simulation..

5.16.3 Measurement accuracy

A. The development object must have at least the following accuracies over the complete temperature
range for the following available measured variables:
Sensor Accuracy
Temperature sensor +- 2%

5.16.4 Electrical operating conditions

A. All further electrical requirements are defined in the document “HWQ Plan” referred in chapter 8.3. L.

5.17 Climatic Requirement

5.17.1 Climatic operating conditions

A. The PMSM shall be able to operate in ambient temperature range:
a. Tmin: - 20°C
b. Tmax: + 50°C
B. The PMSM shall be sable to be stored in ambient temperature range:
a. Tmin: - 40°C
b. Tmax: + 80°C
C. The PMSM shall be designed for operation at the ambient air pressure specified below:
a. Minimum ambient pressure: TBD
b. Maximum ambient pressure: TBD
D. The PMSM shall withstand all further climatic operating requirements defined in the document “HWQ
Plan” referred in chapter 8.3. L.

5.18 Service Requirements (must be defined between KTM and Baumueller)

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A. Baumueller shall ensure availability of replacement parts over the complete lifecycle of the PMSM
B. The parts that shall be made available are defined in the document “Replacement Parts”

5.19 Transport Protection (must be defined between KTM and Baumueller)

A. transportation protection cap must be used for the unplugged connections. At least IP3x shall be met
in accordance with ISO 20653.
B. Transport protection shall be in compliance to “KTM Packaging Specification”
C. Transport protection shall ensure that no part of the delivered component is damaged in any way
D. Specific agreement for the transport protection shall be found between KTM and Baumueller during
the C-sample stage

5.20 Quality Assurance Requirements

A. The following functionalities shall be tested during the End of line (EOL) test for each Component
a. all output ranges
b. Tightness check
c. Insulation resistance
d. Inductance test
e. No Load BEMF test
f. Balancing grade of rotor
[Note]: must be defined between KTM an Baumueller
B. These tests can be adapted or extended and shall be agreed between KTM and Baumueller.
C. Baumueller shall develop a suitable concept regarding the End of line tests which shall be agreed
by KTM.
D. The agreed upon range of tests are defined in the document “Baumueller EOL Test Plan”
E. The test result of the EOL test shall be traceable on Baumueller side by the serial number of each
delivered component.
F. Baumueller confirms that a visual inspection after delivery and a no load Back EMF test at KTMs
EOL testing is sufficient to assure the quality of the component
G. The full envelope of intended EOL testing during the production at KTM will be shared in the
document “KTM EOL Test Plan”. This document shall be checked and confirmed by Baumueller
regarding sufficient coverage of damage identification.

H. Baumueller shall guarantee traceability of all following parts used for the assembly:

a. TBD

6 Testing and Validation

6.1 Test Equipment and Test Mules

Baumueller shall define all test equipment and test mules used during all development stages

6.2 Testing Plan

A. The testing (for A-, B-, and C- samples) is defined by the Hardware Qualification Plan(HWQ) and the
Validation & Verification Plan (V&V)
B. Baumueller shall deliver a testing plan (for A-, B-, C- and D- samples) with timing of each
test and time schedule

6.3 Test specification requirements

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A. Baumuellers shall provide a test specification for all tests listed in the testing plan.
B. The test specification shall include at least following information:
a. Prototype stage of the DUT (devices under test)
b. Number of DUT.
c. Environmental conditions.
d. Expected test result.
e. Operational mode.
f. Test equipment, tools

6.4 Vehicle Testing

A. Vehicle level testing should be conducted by KTM
B. Relevant information and results for the full scope of the development shall be requested in detail by
Baumueller in the form of test descriptions, expected logged values and pass criteria

6.5 Virtual Testing and Simulation

A. Baumueller shall conduct simulation to confirm the compliance of the PMSM to the mechanical
requirements (eg. Load Collective)
B. Baumueller shall conduct simulations to identify possibilities for weight savings and translate them to
the design according to chapter 2.2 D
C. Baumueller shall provide a simulation of all electromagnetic properties of the PMSM

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7 Definitions, Terms, Acronyms

APS Accelerator Position Sensor

BLAC Brushless AC Machine
BLDC Brushless DC Machine
BMS Battery Management System
CRS Component Requirement Specification
DIA Development Interface Agreement
DMU Digital Mock-Up
DUT Device Under Test
DVP Design Verification Plan
DVP&R Design Verification Plan and Report
ECU Electronic Control Unit
E/E-Component Electric-/Electronic Component
ETD Embedded Temperature Detector
EM Electro Magnetic
EMC Electro Magnetic Capability
EOL End of Line
ESD Electrostatic Discharge
FMEA Failure Mode and Effects Analysis
FMEDA Failure Modes Effects and Diagnostic Analysis
FSC Function Safety Concept
FTA Fault Tree Analysis
HMI Human-Machine-Interface
HW Hardware
HWQ Hardware Qualification
HSI Hardware Software Interface
IEC International Electrotechnical Commission
IP International Protection (code)
ISO International Standards Organization
MDU Motor drive unit (Inverter)
MTPA Maximum Torque Per Ampere
MTPV Maximum Torque Per Volt
OEM Original Equipment Manufacturer
P0 P0 vehicle is for the concept approval
P1 P1 vehicle is for the definition of the vehicle specification
P2 P2 vehicle is for the approval of the vehicle geometry and specification
P3 P3 vehicle is from serial tooling and final technical approval
PMSM Permanent Magnet Synchronous Machine
PSW Part Submission Warrant Parts
PTW Powered Two Wheeler
QM Quality Management
QSVSTD KTM Standard Quality Assurance Agreement

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RPS Rotor Position Sensor

SW Software
SEP Standard Entwicklungs Prozess = KTM standard development process
THD Total Harmonic Distortion
TS Technical Specification
TSC Technical Safety Concept
VCU Vehicle Control Unit
VDA Verband der Automobilindustrie
V&V Validation and Verification

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8 Further Applicable Documents

8.1 Normative references

A. The following referenced documents are indispensable for the application of this document.

8.2 KTM Standards

A. KTM Terms and Conditions for the Purchase of Production Material. This document will be
provided by KTM purchase department.
B. KTM Standard Quality Assurance Agreement (QSVSTD-EE-SYSTEMS). This document will
be provided by KTM purchase department.

8.3 Project Specific Documents (to be define)

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