Direct drive motor · Simulation driving racing simulator base

Solution Positioning

Sim-racing equipment places rigorous demands on drive systems: they must deliver high torque and millisecond-level force feedback response to precisely replicate subtle driving cues—such as road bumps, tire friction, and vehicle dynamics—while ensuring low noise levels and stability during prolonged, continuous operation. These systems must also cater to diverse use cases, ranging from professional driver training and esports competitions to high-end consumer entertainment. Traditional industrial servo motor solutions suffer from significant drawbacks—including high torque ripple, cogging torque interference, stiff handling, and poor NVH (Noise, Vibration, and Harshness) performance—making them ill-suited to the demands of sim-racing, which requires an ultra-realistic driving experience. Leveraging its proprietary, full-stack direct-drive technology, Benmo Tech has developed customized direct-drive motors and powertrain solutions specifically for sim-racing applications, providing a high-performance power core for racing simulation wheelbases.

Proposal Design

Rejecting the approach of simply adapting off-the-shelf industrial motors, Direct Drive Tech undertook a comprehensive ground-up development process—encompassing the motor unit, encoder, driver, thermal management system, and control algorithms—specifically tailored to the four core requirements of sim racing: steering feedback, torque output, dynamic response, and thermal safety.

Dual-Skewed Pole Electromagnetic Structure: Features a dual-skew design (skewed stator and rotor poles) that optimizes cogging torque; this significantly suppresses torque ripple and electromagnetic vibration while reducing operating noise, ensuring smooth steering feel free from unwanted vibrations and enhancing overall NVH performance.
Ultra-High Torque Density Integrated Design: Utilizes a high-permeability core and powerful NdFeB magnets, with optimized air-gap ratios and slot fill factors, to deliver robust torque output within a compact form factor—covering peak torque requirements ranging from 10 Nm to 18 Nm.
High-Precision Sensing and Ultra-Fast Response: Equipped with a high-resolution optical encoder and a dual-core processing unit, the system achieves a torque response rate of 9.5 Nm/ms; it captures subtle steering inputs with near-zero latency in force feedback response, faithfully reproducing high-frequency road surface details.
Intelligent Thermal Control and Safety System: Incorporates high-frequency sampling NTC temperature sensors to monitor system temperature in real-time, ensuring stable operation of the motor and control electronics during prolonged, high-intensity racing; includes a dedicated safety mode to balance the needs of professional competition with safety for casual users.
Open and Expandable Powertrain Architecture: The powertrain design supports future expansion, accommodating mechanisms such as quick-release mounts and magnetic contacts for rapid steering wheel swapping, thereby facilitating product iteration and functional upgrades.
Deeply Optimized Force Feedback Algorithms: Integrates vehicle dynamics models and utilizes algorithms refined specifically for racing simulation scenarios to realistically replicate physical vehicle dynamics, such as uneven road surfaces, tire slip, and suspension damping.

Project Value and Implementation Outcomes

Ultra-realistic control experience: Faithfully reproduces subtle road textures, tire grip variations, and vehicle dynamics. The force feedback is smooth and nuanced, balancing powerful output with intricate detail to meet the rigorous standards of professional driver training and competitive esports.
Exceptional long-term reliability: Features a direct-drive architecture without gear reducers, eliminating drivetrain wear at the source. An ultra-low torque ripple design ensures consistent performance during prolonged operation without degradation, resolving issues like backlash and jitter common in traditional systems.
Versatile application across scenarios: A single powertrain solution supports diverse use cases—ranging from home entertainment and professional driver training to commercial driving simulation. It accommodates the development of product versions with varying torque specifications, helping OEMs shorten product R&D and iteration cycles.
Comprehensive end-to-end delivery: Direct Drive Tech offers full-service capabilities—spanning custom requirements, electromagnetic simulation, prototype iteration, mass production, and commissioning/maintenance. We provide complete direct-drive powertrain solutions to OEMs, enabling their end products to achieve world-class technical standards.