John in CR
100 TW
I'm bringing a stator to be rewound on Monday, and I plan to terminate them and install halls myself. The factory installed the halls at 120° intervals between gaps in the stator teeth, which I plan to copy. It doesn't matter which tooth I use as a starting point does it?
I don't understand the purpose of hall circuit boards. From the factory these motors don't have them, and the hall wires just go straight to the axle where the gnd and +5v of the three are combined to go through the axle. Is there any potential advantage of robbing a hall circuit board from a dead motor to install on this one?
I know to take care that all 3 hall sensors are mounted facing the same direction, and I'll copy the depth the factory used, since they attained 93% peak efficiency. That high efficiency was despite the extra resistance losses of the ingenious 2 speed (series/parallel) manual switching mechanism where they separated the copper strands into 2 groups for each phase, and achieved the switching with a set of 2 position rings with spring loaded contacts and a shaft to through the axle on the non-wire side. I'm doing away with the switching which was the failure prone point of the motor.
Since the rewind will almost double the Kv, I can make use of the hole for the shifting shaft to bring one of the thicker phase wires required outside of the motor. I'm lucky that hole exists, so I don't have to make a new axle and use larger bearings with greater parasitic losses, so I hope to increase efficiency a bit with this rework as well as more than double its power handling at 78V. With the 2 speed contacts soldered in high position retaining the relatively long and thin transitions copper in the switching mech, and poor ventilation these have been run without issue at over 12kw, so with better ventilation and a higher Kv I think it should handle whatever a Thermo Nucular 24fet controller can throw at it. 8)
I don't understand the purpose of hall circuit boards. From the factory these motors don't have them, and the hall wires just go straight to the axle where the gnd and +5v of the three are combined to go through the axle. Is there any potential advantage of robbing a hall circuit board from a dead motor to install on this one?
I know to take care that all 3 hall sensors are mounted facing the same direction, and I'll copy the depth the factory used, since they attained 93% peak efficiency. That high efficiency was despite the extra resistance losses of the ingenious 2 speed (series/parallel) manual switching mechanism where they separated the copper strands into 2 groups for each phase, and achieved the switching with a set of 2 position rings with spring loaded contacts and a shaft to through the axle on the non-wire side. I'm doing away with the switching which was the failure prone point of the motor.
Since the rewind will almost double the Kv, I can make use of the hole for the shifting shaft to bring one of the thicker phase wires required outside of the motor. I'm lucky that hole exists, so I don't have to make a new axle and use larger bearings with greater parasitic losses, so I hope to increase efficiency a bit with this rework as well as more than double its power handling at 78V. With the 2 speed contacts soldered in high position retaining the relatively long and thin transitions copper in the switching mech, and poor ventilation these have been run without issue at over 12kw, so with better ventilation and a higher Kv I think it should handle whatever a Thermo Nucular 24fet controller can throw at it. 8)