Science, Physics, Math, & Myth

John in CR said:
First, the motor has already been dyno tested by Hillsofvalp. Second and more importantly, simple measurements and straight forward calculations prove the factory's test info to be true. Kv gives us Kt, torque/amp. Phase-to-phase resistance gives us copper losses. No-load currents give us all the other losses, hysteresis, eddy currents, windage, bearing friction, etc, and those vary with rpm in a manner that no-load current at 2 different rpm gives us the breakout to predict these losses at any rpm.

would it be possible to calculate peak efficiency out of this spreadsheet?
having the motor in the simulator would mean we can simple compare it with others, changing wheel diameter current and volts and see what happens. its a pity you do not want to support this.
 
madin88 said:
would it be possible to calculate peak efficiency out of this spreadsheet?
Column Q.

having the motor in the simulator would mean we can simple compare it with others, changing wheel diameter current and volts and see what happens. its a pity you do not want to support this.
Maybe try crossbreak's open source simulator.

I don't blame John for not wanting the expense of donating motors or the hassle of crowdfunding them - if it's that important to you then maybe you should "support this" by arranging the funding so that John could just deal with it as a normal purchase.
 
Yeah your MidMonster (14KV) motor looks interesting John in CR
https://endless-sphere.com/forums/viewtopic.php?f=31&t=47607&hilit=Midmonster#p698336
.....and the Monster (16KV) looks even MORE interesting
https://endless-sphere.com/forums/viewtopic.php?f=31&t=46898&hilit=Monster#p686592
....Oh and the MiniMonster https://endless-sphere.com/forums/viewtopic.php?f=31&t=40859
sure beats my 9KV MXUS, with those speeds almost 1.5-1.8 times the KV, I bet its an awesome motor!


You still sell those, I see those threads are a couple years old. The KV is high, massive copper in there would need a moto rim for sure.

You say only one KV for that motor the company sells, and for good reason, thats all you need when building around it.
 
cycborg said:
madin88 said:
would it be possible to calculate peak efficiency out of this spreadsheet?
Column Q.

That computes peak efficiency for the listed rpm. With a small wheel and high voltage I run HubMonster significantly higher, so peak efficiency is higher too. I find columns AD thru AJ the most useful, because I can input different rpm and torque numbers and see the results for power, heat, and efficiency. That's where the benefits of running a smaller wheel become glaringly obvious, because the reduced gearing increases rpm and decreases the torque requirement.
 
If you put a fast turn motor, lets say on a skateboard, so instead of 250kv and 22 volts as is typical, it's 1000kv and run with 6 volts.


It would need many more amps in the volts x amps equals watts equation to perform similarly . And it could get take those amps being thicker wires. But ultimately more amps are used and the battery gets depleted faster?
 
Hummina Shadeeba said:
If you put a fast turn motor, lets say on a skateboard, so instead of 250kv and 22 volts as is typical, it's 1000kv and run with 6 volts.


It would need many more amps in the volts x amps equals watts equation to perform similarly . And it could get take those amps being thicker wires. But ultimately more amps are used and the battery gets depleted faster?

The same energy fits in the same size battery, so 10ah22V is the same size as 36.7ah6V. Therefore the battery gets depleted at the same rate.
 
Hummina Shadeeba said:
ok. yea more amps in there to begin with. so why don't people run 4 volts in such a scenario?

with current available controllers it is better to up the voltage and low the amps for overall higher efficiency. also it would be quite challenging to deal with very large gauge wires (think of soldering for instance)
typically 10-14s for RC and about 20-22s for ebike controller does have the biggest power density at the moment.
 
At 4V, youd need 100 amps for 400W, huge wires needed.
--------------------------
Hey Im just listening to icecube57 on his podcast.
Around 33 minutes to 37 minutes, around 36 minutes was interesting. 39-41 minutes is good. 43 minutes.
https://www.youtube.com/watch?v=4Xj-tcyJWsI

Interesting. He was talking about high kv for flat terrain and low kv for hilly terrain. Picking the right kv for the terrain. Picking the right voltage. Over saturation of the motor at voltages over 20S. 18-20S is good to be at for most motors. Picking the butter zone, to be more efficient.

Looks like icecube57 is using 4T 18fet and 67 volts on the mxus 3000w.
 
OMG! Enough of the mythology stuff. Learn the quite simple physics and stop paying attention to people who don't understand it. Different windings are not a change in gearing, period.

markz said:
At 4V, youd need 100 amps for 400W, huge wires needed.
--------------------------
Hey Im just listening to icecube57 on his podcast.
Around 33 minutes to 37 minutes, around 36 minutes was interesting. 39-41 minutes is good. 43 minutes.
https://www.youtube.com/watch?v=4Xj-tcyJWsI

Interesting. He was talking about high kv for flat terrain and low kv for hilly terrain. Picking the right kv for the terrain. Picking the right voltage. Over saturation of the motor at voltages over 20S. 18-20S is good to be at for most motors. Picking the butter zone, to be more efficient.

Looks like icecube57 is using 4T 18fet and 67 volts on the mxus 3000w.
 
Perhaps I heard it wrong then typed it out wrong, my hearing aint the best. I listened to all of his podcasts, 6 or 7 of them. It will be cool to see what other members of E.S. he gets to collaborate with him on his podcasts.
 
John in CR said:
OMG! Enough of the mythology stuff. Learn the quite simple physics and stop paying attention to people who don't understand it. Different windings are not a change in gearing, period.

John, you have been obsessing over this "myth" topic too much, I'm afraid.
:roll:
Different windings of the same motor design change the Kv or rotational speed per volt of a motor. Just as the winding changes the torque per amp of current. Controller size, wire gauge, battery complexity. It all has to be factored in.
Once you really understand how every part of a system works together, you realize you can do whatever you want. Decide which constraint is most limiting for your particular project then choose your other system components around that constraint to suit your goals. The motor winding is only a constraint if you've already purchased it. Otherwise treat it as a variable, just like voltage, current and tire size.
 
teslanv said:
John in CR said:
OMG! Enough of the mythology stuff. Learn the quite simple physics and stop paying attention to people who don't understand it. Different windings are not a change in gearing, period.

John, you have been obsessing over this "myth" topic too much, I'm afraid.
:roll:
Different windings of the same motor design change the Kv or rotational speed per volt of a motor. Just as the winding changes the torque per amp of current. Controller size, wire gauge, battery complexity. It all has to be factored in.
Once you really understand how every part of a system works together, you realize you can do whatever you want. Decide which constraint is most limiting for your particular project then choose your other system components around that constraint to suit your goals. The motor winding is only a constraint if you've already purchased it. Otherwise treat it as a variable, just like voltage, current and tire size.
Yes but what John is trying to point out is the torque limit of the motor does not change the max torque with 2 motors that have different windings will be the same as long as you still fit the same copper fill in. You will need a controller that can do more phase amps for one with a higher kv but that's no big deal in most ebike situations.
 
Not only does the torque limit not change, but the amount of heat (our real limitation) to make a given amount of torque is the same.

All the crap about slow wind motors being better for hills or that they make you able to run a larger diameter wheel is complete BS, because it's no different than saying they make more torque. It remains a widespread misunderstanding, and there are still people still teaching different wording of the myth like they know WTF they're talking about. It's not being obsessive. There's right and there's wrong, and wrong should be unacceptable to everyone.
 
what about a situation in which the kv was way high (maybe 1000kv for a skateboard hub motor) and the voltage wasn't dropped accordingly. What happens?
 
Hummina Shadeeba said:
what about a situation in which the kv was way high (maybe 1000kv for a skateboard hub motor) and the voltage wasn't dropped accordingly. What happens?
Still the same peak torque limit and the same heat produced at a given rpm from the motor.
 
John in CR said:
Not only does the torque limit not change, but the amount of heat (our real limitation) to make a given amount of torque is the same.

All the crap about slow wind motors being better for hills or that they make you able to run a larger diameter wheel is complete BS, because it's no different than saying they make more torque. It remains a widespread misunderstanding, and there are still people still teaching different wording of the myth like they know WTF they're talking about. It's not being obsessive. There's right and there's wrong, and wrong should be unacceptable to everyone.

When specifying a complete system from scratch you would consider All of the constraints and all of the variables.
If a customer wants a large diameter tire (I.e. Fat Bike) and slow speeds (less than 30mph), does it make any MORE sense to pair it with a high Kv motor and very low voltage and high current, rather than a low Kv motor, moderate voltage (less than 60V) and low current? I would argue not, since a lower current system would require a less powerful (less expensive) controller and smaller battery and phase wires. Keep it simple, stupid.

If "performance" is the same, then why not design to minimize cost and maximize appearance?
 
teslanv said:
John in CR said:
Not only does the torque limit not change, but the amount of heat (our real limitation) to make a given amount of torque is the same.

All the crap about slow wind motors being better for hills or that they make you able to run a larger diameter wheel is complete BS, because it's no different than saying they make more torque. It remains a widespread misunderstanding, and there are still people still teaching different wording of the myth like they know WTF they're talking about. It's not being obsessive. There's right and there's wrong, and wrong should be unacceptable to everyone.

When specifying a complete system from scratch you would consider All of the constraints and all of the variables.
If a customer wants a large diameter tire (I.e. Fat Bike) and slow speeds (less than 30mph), does it make any MORE sense to pair it with a high Kv motor and very low voltage and high current, rather than a low Kv motor, moderate voltage (less than 60V) and low current? I would argue not, since a lower current system would require a less powerful (less expensive) controller and smaller battery and phase wires. Keep it simple, stupid.

If "performance" is the same, then why not design to minimize cost and maximize appearance?


As it's all the same to the motor, pick the KV that works with your battery and controller for intended operating speed range.

Going any higher KV than needed (like 200mph no-load for a vehicle with the power to only achieve 50mph) doesn't mean worse motor performance, but it does mean the controller needs to be unnecessarily larger than needed for the intended 0-50mph operating window.

There is no winding choice or voltage to run that somehow cheats physics. The whole trick is just finding a reasonable balance with what parts you've got available for the application.
 
I just want to end the statements by those who should know or learn better that are different wording of the torque wind vs speed wind myth. Examples are things like "use fast wind motors to go fast and slow winds to climb hills" or "use a slow wind to run a bigger wheel".

There's an inordinate amount of discussion about which wind to use, when (except at the ends of the spectrum) it doesn't make a hill of beans difference. All that discussion should be replaced with discussions of gearing and load, especially wrt current limits...the stuff that makes a real difference.

The funniest part about offering different windings is how there always seems to be one optimum with the most copper, and the factories get lazy or cheap out with all the special requests for windings that end up with less copper around the teeth. I could have overlooked the 1 strand difference that was less than a 2% difference in resistance, but when laziness/cheapness turned it into a 4 strand difference (an over 6% increase in resistance) my try one out decision turned into an "I'll pass".

Teslanv, you really don't want to bring up that there's a lower cost to run a slow wind motor. That topic is best just dropped. Also, the battery isn't any smaller either.
 
John in CR said:
Teslanv, you really don't want to bring up that there's a lower cost to run a slow wind motor. That topic is best just dropped.

With a Low Kv (High Kt) motor, you can use a lower current (Less FETs) controller and smaller battery & phase leads, than a comparable High Kv motor, which requires MORE current to provide the same torque as the low Kv winding.
The battery for either could be the same total watt-hour capacity, but with higher voltage and lower capacity on the slow wind and lower voltage and higher capacity on the fast wind. So yes, the battery cost is more or less irrelevant in the comparison, unless you want to argue about the cost of a 10S BMS vs a 16S BMS.

John, why is it so hard for you to admit that a slow-wind motor is a more appropriate winding choice for certain applications?

liveforphysics said:
Going any higher KV than needed (like 200mph no-load for a vehicle with the power to only achieve 50mph) doesn't mean worse motor performance, but it does mean the controller needs to be unnecessarily larger than needed for the intended 0-50mph operating window.
 
John in CR said:
There's an inordinate amount of discussion about which wind to use, when (except at the ends of the spectrum) it doesn't make a hill of beans difference. All that discussion should be replaced with discussions of gearing and load, especially wrt current limits...the stuff that makes a real difference.

I have very clearly spelled out the current limits of the different windings of the MXUS motors.

https://endless-sphere.com/forums/viewtopic.php?f=2&t=63142&start=1275#p1062179

The current limit of each winding is also listed on my website.
 
teslanv said:
John in CR said:
Teslanv, you really don't want to bring up that there's a lower cost to run a slow wind motor. That topic is best just dropped.

With a Low Kv (High Kt) motor, you can use a lower current (Less FETs) controller and smaller battery & phase leads, than a comparable High Kv motor, which requires MORE current to provide the same torque as the low Kv winding.
The battery for either could be the same total watt-hour capacity, but with higher voltage and lower capacity on the slow wind and lower voltage and higher capacity on the fast wind. So yes, the battery cost is more or less irrelevant in the comparison, unless you want to argue about the cost of a 10S BMS vs a 16S BMS.

John, why is it so hard for you to admit that a slow-wind motor is a more appropriate winding choice for certain applications?

I'm totally with you teslanv. IMO John got stuck in his believs and is not able to look outside the box :p
Another example would be mxus 3T at 60V vs. 4T at 80V. Latter would be the better choice for performance per costs and system efficiency (less losses over phase wires). And it is not the same if a controller works at 50% PWM (high kV with limited speed) or 100% (without speed limit). Consumption during acceleration (top end) is different, the 100% PWM system has higher efficiency because no additional step down losses.
It is not always about maximum hot rodding. the motors we are talking are "only" 3kW cont, 6kW peak rated for ebike / e-moped and no 10kW+ motorcylce motor like Hubmonster is, so for most applications and together with at the moment highest power dense 100V controllers the fastest motor rarely would be the best choice.
 
The lower the KV the more resistive the windings are, higher the KV the less resistive the windings are.
The sooner the motor over heats in lower KV.

MXUS XF40-45H "3000W" Direct Drive Hub Motor Series:

3T:
Max. Continuous Phase Current: 55A
Overheat in 10 Minutes: 85A
Overheat in 60 seconds: 242A

4T:
Max. Continuous Phase Current: 42.6A
Overheat in 10 minutes: 66A
Overheat in 60 seconds: 186A

5T:
Max. Continuous Phase Current: 34.9A
Overheat in 10 minutes: 51.6A
Overheat in 60 seconds: 150A

6T:
Max. Continuous Phase Current: 30.3A
Overheat in 10 minutes: 47A
Overheat in 60 seconds: 132A

Generic Winding Phase Current Limits per strand:
Max. Continuous Phase Current: 2.84A per strand
Overheat in 10 minutes: 4.4A per strand
Overheat in 60 seconds: 12.4A per strand

*All data assumes a non-vented hub motor. Venting or other methods of cooling should increase these values.
 
madin88 said:
teslanv said:
John in CR said:
Teslanv, you really don't want to bring up that there's a lower cost to run a slow wind motor. That topic is best just dropped.

With a Low Kv (High Kt) motor, you can use a lower current (Less FETs) controller and smaller battery & phase leads, than a comparable High Kv motor, which requires MORE current to provide the same torque as the low Kv winding.
The battery for either could be the same total watt-hour capacity, but with higher voltage and lower capacity on the slow wind and lower voltage and higher capacity on the fast wind. So yes, the battery cost is more or less irrelevant in the comparison, unless you want to argue about the cost of a 10S BMS vs a 16S BMS.

John, why is it so hard for you to admit that a slow-wind motor is a more appropriate winding choice for certain applications?

I'm totally with you teslanv. IMO John got stuck in his believs and is not able to look outside the box :p
Another example would be mxus 3T at 60V vs. 4T at 80V. Latter would be the better choice for performance per costs and system efficiency (less losses over phase wires). And it is not the same if a controller works at 50% PWM (high kV with limited speed) or 100% (without speed limit). Consumption during acceleration (top end) is different, the 100% PWM system has higher efficiency because no additional step down losses.
It is not always about maximum hot rodding. the motors we are talking are "only" 3kW cont, 6kW peak rated for ebike / e-moped and no 10kW+ motorcylce motor like Hubmonster is, so for most applications and together with at the moment highest power dense 100V controllers the fastest motor rarely would be the best choice.

sorry mate you got halfway through being right, then lost it again...

" Latter would be the better choice for performance per costs and system efficiency (less losses over phase wires)"
assuming you change battery voltage and controller accordingly, and all other wiring remains the same, yes... but the difference will be pretty minor in practice.

" And it is not the same if a controller works at 50% PWM (high kV with limited speed) or 100% (without speed limit). Consumption during acceleration (top end) is different, the 100% PWM system has higher efficiency because no additional step down losses."
Nope. sorry, but if you vary the voltage and current by the same ratio as the change in KV, then the duty cycle at a given speed/power demand will remain the same, as both motors will be spinning at the same % of their no load speed, with the same back EMF (as a % of pack voltage) same (relative) resistance and inductance. if your just comparing a high kv and low kv motor with the same battery/controller combo for each then yes, it'll have a small difference. again however you're unlikely to notice it unless the controller is struggling with the high kv motor's R and L.

"Consumption during acceleration (top end) is different, the 100% PWM system has higher efficiency because no additional step down losses."
Nope, it'll be the same, as each controller is stepping down the same relative voltage, to the same relative phase voltage, in order to generate the same phase current, and thus the same motor torque (and same motor heat). Again however if your using the same controller and battery for each motor there will be a small difference, but again, this will be small.

"It is not always about maximum hot rodding. the motors we are talking are "only" 3kW cont, 6kW peak rated for ebike / e-moped and no 10kW+ motorcylce motor like Hubmonster is, so for most applications and together with at the moment highest power dense 100V controllers the fastest motor rarely would be the best choice."
really its only a choice based on what your controller can handle. if your controller is capable of running low resistance and inductance motors at high loads and low duty cycles then there's really very little difference between motor KV's. As has been stated repeatedly, there's no difference in heat generation between a low and high kv motor for a given torque output. Basically, choose a kv that wont cause your controller to kill itself, while still giving you the top speed you desire for a given wheel size. then tune your controller perimeters accordingly, and you'll get the max power you can for a given rpm/controller/battery combo.

you could use a higher kv motor, with a smaller wheel, and get more power, but then you're wheels smaller (not good for offroad etc)
you could use a lower kv motor, but then your top speed will be lower.
you could use a higher kv motor with the same wheel, but your controller may not be able to run such a motor at such low rpms (low rpm means low back emf and thus lower duty cycle, and more heat/damange, though this is highly dependant on the controller).

However, in NONE of these situations will the motors torque per unit heat change. So if it takes 3kw to maintain your top speed, then every one of these cases will produce the same heat, with the minor exception of the first which will be lower. This is due purely to a larger reduction stage to the road (smaller wheel) which means the motor needs to produce less torque (same power at higher rpm = less torque), thus less heat.

it cant be escaped... motor continuous torque is the same for any kv (well not quite, but the difference is so small you'll never notice outside of a lab). So again, pick a kv based solely on what your controller can handle while still giving the speed you want with a given wheel size. if your controllers so weak that you cant hit your desired speed with a kv that it can handle, then get a better controller, or deal with the lower speed. if your controllers good enough that it can handle a motor that provides a speed higher than desired, then drop your battery votlage and save on BMS and wiring complexity, or leave it and be happy with the greater high torque near your top speed (lower back EMF means more phase current, thus more torque), or get a lower voltage controller. The motor doesn't care in any case.
 
your not (or rather this test isn't) comparing like with like.
assuming the same copper fill, your getting about 10% more torque out of the 6 turn in that test than the 3 turn as the amp turns are 10% higher (47A x 6T/3T = 94A... 94/85=1.1). 10% more torque for the same time to overheat (or rather, same heat generated). It would appear from this data that the 6T is the most powerful version of this motor, as it has the greatest torque per unit heat. It may mean running a prohibitively high voltage in order to get your desired top speed however...

markz said:
The lower the KV the more resistive the windings are, higher the KV the less resistive the windings are.
The sooner the motor over heats in lower KV.

MXUS XF40-45H "3000W" Direct Drive Hub Motor Series:

3T:
Max. Continuous Phase Current: 55A
Overheat in 10 Minutes: 85A
Overheat in 60 seconds: 242A

4T:
Max. Continuous Phase Current: 42.6A
Overheat in 10 minutes: 66A
Overheat in 60 seconds: 186A

5T:
Max. Continuous Phase Current: 34.9A
Overheat in 10 minutes: 51.6A
Overheat in 60 seconds: 150A

6T:
Max. Continuous Phase Current: 30.3A
Overheat in 10 minutes: 47A
Overheat in 60 seconds: 132A

Generic Winding Phase Current Limits per strand:
Max. Continuous Phase Current: 2.84A per strand
Overheat in 10 minutes: 4.4A per strand
Overheat in 60 seconds: 12.4A per strand

*All data assumes a non-vented hub motor. Venting or other methods of cooling should increase these values.
 
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