LeftieBiker said:You are either misunderstanding some basics here, or just love to argue and obfuscate. I don't plan on spending long on this, but here goes for a short reply:
The controller (inverter) can't create energy, and the motor is not typically way over-designed to significantly increase its power
output with just a controller redesign. As I mentioned, the controller's firmware may limit some max power output, but little
can be gained without the battery being capable of supplying the necessary peak energy input - peak current continuously.
You don't understand (or are misrepresenting) where the 'bottleneck' is here for power flow. It isn't the battery, and it isn't primarily the controller. It is the inverter. Nissan wasn't trying to design a 200HP Hot Hatch with a 50 mile range when they put the original Leaf into production, and they still weren't trying for more power until the 2018 redesign. So they gave the drivetrain an inverter that balances cost, performance, and energy economy. They could have given the 30kwh Leaf 147HP, or even the 24kwh Leaf, but the marked drop in range with any spirited driving at all would have been bad for the car's reputation. You do have half a point, though: the 40kwh pack was needed before the inverter output was boosted, because they needed the extra capacity for adequate range with the extra power. I know that you think you know what's going on with C rates and voltages, and you seem to understand the concepts. You just don't understand how battery capacity relates (and doesn't relate) to horsepower in a modern, non-racing EV.
I think that once the 40kwh pack is transplanted into Gen I Leafs by backyard EV mechanics, they will be happy to discover that the range is closer to 200 miles than to 150 - mainly because of the smaller inverter.
From Ars Technica, when the 2018 came out (Nissan seems to have stopped mentioning the inverter early in 2018):
New powertrain
The outgoing Leaf might have sold well, but there's no escaping the fact that, by 2017's standards, it was outdated technology. The electric motor has been carried over, but there's a new inverter, among other improvements. Power output is boosted from 80kW (107hp) to 110kW (147hp), and it's more torquey—320Nm (236ft-lbs) in the 2018 versus 254Nm (187ft-lbs) in the old model.
You're obfuscating the key issues:
1. The controller and the inverter are the basically the same elements, i.e. it's just a matter of nomenclature.
2. Energy output is <= energy input
3. HP (horsepower) = Torque X RPM X Constant = Power = Energy per unit of Time
4. Energy = Power over Time = Integral of Power times dT
5. HP x T = Energy = kWh = Volts (supplied to the motor) x Amps (supplied to the motor - peak) x Time
PM (permanent magnet) Motor
1. The output torque is limited by the magnetic field developed by the PM (permanent magnets) and the magnet field developed
in the stator by the battery voltage (~360 volts) and the battery's current supplied via the motor controller & a phase angle of the field
2. The stator's magnetic field is a function of the current developed in the stator via the controller (inverter) per unit time.
3. The controller is basically a time controlled switch that applies the battery voltage to the stator (phase-related), which results
in a field current. The maximum field current is related to the field inductance and the peak current of the field over time.
Bottom line: Maximum motor HP of the Leaf PM motor:
a. overall limitation - power input - battery voltage and peak battery current, & the magnet field of the magnets and stator
b. controller maximum design limit - the driver semiconductors Vmax & Imax, and power losses (switching times/Vsat)
c. firmware preset max field current limit <= to controller maximum design limit AND the peak battery current & battery resistance
d. maximum magnetic field developed by the permanent magnets and stator's magnetic field
e. motor load - vehicle overall weight/losses, and motor gearing