Adding hall sensors to outrunners

[Arlo1]

Very cool guys

[minuteman2k]

Gwhy

When will a kit be available??

Yhis is great for all RCers

[gwhy!]

Gwhy

When will a kit be available??

Yhis is great for all RCers

I have been playing around with a smaller version complete with mount, results are good, so these smaller versions will be available to buy should anyone want them, I have tested them on 63mm dia motors and on the larger 80mm dia motors. I need to make myself around 12 of these so I will be ordering the hall sensors soon. If anyone else would like one then please express your interest before I order my halls ( in a weeks time ). I will update the thread in the for sell section of the forum viewtopic.php?f=31&t=36149 .

[gwhy!]

Hall sensors ordered.

[gwhy!]

hall sensors arrived, and I have made a start
On schedule to have them all finished by the end of this week.

bunch of hall sensors.jpg (113.52 KiB) Viewed 1377 times

[milesinfront]

They look GREAT!

[gwhy!]

I have finished them, I just need to test them all and try to right up some instructions on the best way to set them up, then they are good to go

[milesinfront]

I'm super keen! Got a 63mm motor on it's way from LeaderHobby... My 36v 1020 motor melted today! Ready to start life over with r/c power....

[gwhy!]

After much testing and trying to find a easy way of setting them up I have decided to produce the larger ones for the masses ( the larger ones were much, much easier to setup and have more predicable results ) . I will keep the smaller ones for my own projects as they do work but requires the use of a scope and a lot of patience to setup correctly. This means that the time scale have changed to get these new ones out but hopefully not by much. maybe a week or 2 as I already have the moulds and the halls its just a matter of finding the time to put them together. Sorry guys

[Thud]

Gwhy,
you say larger ones....does that mean 80mm motors? or another version of your 63mm units? I am eching boards to hold the halls & wires in my v2 molds myself....your way ahead of me though.

[liveforphysics]

hall sensors arrived, and I have made a start
On schedule to have them all finished by the end of this week.

bunch of hall sensors.jpg

Wow! Those look fantastic! Nice job!

[gwhy!]

Gwhy,
you say larger ones....does that mean 80mm motors? or another version of your 63mm units? I am eching boards to hold the halls & wires in my v2 molds myself....your way ahead of me though.

Hi Thud,
The larger spaced ones , 63mm and 80mm but spaced at 60d

[milesinfront]

Hi Thud,
The larger spaced ones , 63mm and 80mm but spaced at 60d

Phew! My 63mm just arrived today and I thought I was gunna have to make my own hall array...

[tuurb]

hey gwhy,

I am looking for a sensor mount for the hobbyking SK3 63-64 (as HumboldtRc).
I understood you will be selling the brackets mentioned above?

Howmuch would they cost and when are they available?

Thanks,

tuurb

[tuurb]

I am also trying to make my own brackets, wich I will 3d print,
I found on endless sphere that a lot of people use the S411A from Honeywell with 17,14° spacing so I tought to do thesame.
Below my temporally design of a bracket for use on my HK 6364 213rpm/V BLDC motor, I will be using the 150Amp HK car ESC.

I think of installing the mount at a distance of 3mm from the spinning motor:
like this the centerpoint of the sensors will be at around 4,5mm from the outside can of the motor...

Any remarks or ideas?
Maybe another sensor is better for this application?
Or other spacing?
Or another distance between sensor and motor?

(I have zero experience with adding hall sensors, BLDC motors or ESC, but I'll learn!)

Thanks in advance!

Tuurb

[gwhy!]

I am also trying to make my own brackets, wich I will 3d print,
I found on endless sphere that a lot of people use the S411A from Honeywell with 17,14° spacing so I tought to do thesame.
Below my temporally design of a bracket for use on my HK 6364 213rpm/V BLDC motor, I will be using the 150Amp HK car ESC.

I think of installing the mount at a distance of 3mm from the spinning motor:
like this the centerpoint of the sensors will be at around 4,5mm from the outside can of the motor...

Any remarks or ideas?
Maybe another sensor is better for this application?
Or other spacing?
Or another distance between sensor and motor?

(I have zero experience with adding hall sensors, BLDC motors or ESC, but I'll learn!)

Thanks in advance!

Tuurb

Hi Tuurb
your design looks very nice, the halls will be ok for the smaller motors at that distance from the can, but I would say to use a bigger spacing either 60degree but with the center hall flipped or 68.57degrees with all the halls facing the same way. The 17degree spacing placement needs to be very precise to work well , the bigger spacing is a little more forgiving. your brackets may also need 2 ways of adjustment ( distance from the motor can and timing clockwise/anti-clockwise )

cheers.

[tuurb]

thank for the reply Gwhy,

I will reconsider my design and go for the bigger 60° spacing, the clockwise and anticlockwise slipholes will be mounted on my motor bracket...

Greets, Tuur

[gwhy!]

Ok, I have now made a couple of hall sensors for sale ( I will make them as (and if) people still want them ). The hall sensors for the 80mm motors are the larger type ( around 60d ) these work well and are pretty easy to setup (unlike the smaller spacing ) I just need to write up some instructions, as for the 64mm motors the smaller spacing works just as well as the 60d so the hall sensor will remain the smaller type ( again I just need to write up some setup instructions ). So these are now officially complete for the 80mm motors and the 64mm motors.

[spkpn]

Hello,

I might be interested in halls that can be mounted to the turnigy 80-100 series motor. But only if a mechanically untalented guy like me can acomplish the job . What is the price?


rgrds,
spkpn

[gwhy!]

Hello,

I might be interested in halls that can be mounted to the turnigy 80-100 series motor. But only if a mechanically untalented guy like me can acomplish the job . What is the price?


rgrds,
spkpn

Please send me a PM so I get put you on the list and answer and questions that you have.
Cheers, They are £25.00 plus P+P

[asifjahmed]

Hello -

This is the nest thread on the `net for sensoring brushless outrunners it seems! Anyway, I am still waiting for my sensored speed controller to arrive (http://www.hobbyking.com/hobbyking/stor ... r_ESC.html) but in the meantime I got busy drawing the necessary CAD parts and 3d printing them. I am using the 17.14 degree spacing. The motor is a Turnigy Aerodrive SK3 6463-168kv. Signals look nice and clean on the scope. Will keep you posted!

[2moto]

I haven't read the entire thread (too long!!) so this may be blasphemy. Going back a few years, at a brushless motor company we experimented with various types of commutation sensors on brushless motors. By some margin, optical sensors produced far better accuracy which a good controller can use to its benefit for switching phases. Hall effects, although convenient and cheap, have various drawbacks, some of which have already been highlighted in this thread (from the bits I did read).

For this motor, I would design an optical interrupter type arrangement which will work well. Of course, there are dust and environmental issues to solve. But still, for the performance advantage, I would chose this direction. With good shielding, you should be able to get something to work where marks on the spinning "bell" are being picked up by reflective optical sensors located around the periphery.

No, no, no, must resist, must resist! Too many projects!

[Miles]

See: www.endless-sphere.com/forums/viewtopic.php?f=2&t=28966

[gwhy!]

I haven't read the entire thread (too long!!) so this may be blasphemy. Going back a few years, at a brushless motor company we experimented with various types of commutation sensors on brushless motors. By some margin, optical sensors produced far better accuracy which a good controller can use to its benefit for switching phases. Hall effects, although convenient and cheap, have various drawbacks, some of which have already been highlighted in this thread (from the bits I did read).

For this motor, I would design an optical interrupter type arrangement which will work well. Of course, there are dust and environmental issues to solve. But still, for the performance advantage, I would chose this direction. With good shielding, you should be able to get something to work where marks on the spinning "bell" are being picked up by reflective optical sensors located around the periphery.

No, no, no, must resist, must resist! Too many projects!

The optical route has been done and do work ( there is a thread about it, and the optical kits are for sell), but there were to many problems associated with the optical route for me due to real life conditions that these motors are run in, I have used halls for nearly all my projects as hall sensors give predicable results and have worked in all the real life conditions I have subjected the motors to.

edit: there you go Miles have found the thread

[2moto]

See: viewtopic.php?f=2&t=28966

Ah, good, I can now cross that project off my list.