Fan cooled 3220s are finally here!

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Fan cooled 3220s are finally here!

Postby recumpence » Tue Jan 31, 2012 9:13 am

Hey Guys,

The new fan cooled 3220 (3220f) is a reality! I have my first production motor coming. Actually two are coming, one is going to FFR trikes. I should have them in the next few days.

It is basically a 3220 with open front and rear as well as a 1/2 inch shaft and huge bearings. The can is not just a 3220 can opened up, it is a completely new item with thicker front and rear plates that is very opened up as well as using new thermal epoxy and the epoxy is not poured into the motor. The windings are relatively open (not full of epoxy) to allow air to flow around and through the windings. It comes with a CNC machined aluminum fan mounted to the rear shaft protruding from the rear of the motor. The wires exit the side of the can at the rear.

I have not tested the new motor yet. However, with all the changes, it should be good for around 50% more continuous power than without the changes. I have a blinged out DaVinci drive anodized in black set aside for this motor. That drive will use my new larger main pulley as well.

I will post pictures when the motor arrives. :)

Matt

Oh, this system was originally going to be installed on my yellow trike. But, that trike is sold. So, I will be offering up this first run 3220f with black DaVinci drive for sale.
Last edited by recumpence on Fri Feb 03, 2012 7:13 pm, edited 1 time in total.
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Re: Fan cooled 3220s are nearly here!

Postby farmkid4 » Tue Jan 31, 2012 7:38 pm

Do you know what the price will be for the 3220f?

Looking forward to some pics :D
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Re: Fan cooled 3220s are nearly here!

Postby damcard » Tue Jan 31, 2012 7:58 pm

No sensors yet? -Damcard
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Re: Fan cooled 3220s are nearly here!

Postby recumpence » Tue Jan 31, 2012 8:57 pm

No sensors yet (I know, I know, it has been a while). Actually, the sensorless setups have been working so well (up to 10kw), that the "Need" for sensors is not as great. That being said, sensors are coming. But, that is not a huge priority for the 3 inch motors right now.

Oh, as for production cost, that is a good question. This motor cost me a lot because of innitial programming and machining of the first few parts. The prototyping has cost me $1,200+ at this point and that is for mechanical changes and stock 3220 electrical components.

I would think these motors should be around $875 to $900 each if I have production numbers calculated correctly. It is possible they could be less. But, bear in mind, each motor uses a CNC machined aluminum fan as well as a completely custom can and rotor.

Matt
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Re: Fan cooled 3220s are nearly here!

Postby recumpence » Fri Feb 03, 2012 7:09 pm

Here are the first two 3220-f fan cooled motors!

As mentioned in the opening post, these have 1/2 inch shafts, 1-1/8 inch OD bearings, proprietary cans, thermal epoxy with open windings for maximized airflow, and CNC machined aluminum fans.

The one with the silver fan is going to FFR trikes. The black fan motor is going up for sale with a black DaVinci drive. :)

Enjoy!

Matt
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Re: Fan cooled 3220s are finally here!

Postby kfong » Fri Feb 03, 2012 7:17 pm

Nice, finally some RC motors catered to ebikes.
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Re: Fan cooled 3220s are finally here!

Postby Thud » Fri Feb 03, 2012 7:37 pm

Are thouse square across the mounting face? (seald up if mounted to a large plate)
that is actually a great atribute as you can duct your incoming air to keep out rocks & badgers along the trails... I like it.
good looking motors all the way.
get some......

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Re: Fan cooled 3220s are finally here!

Postby damcard » Fri Feb 03, 2012 9:32 pm

That's one sexy motor. You did it again Matt. -Damcard
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Re: Fan cooled 3220s are finally here!

Postby spinningmagnets » Fri Feb 03, 2012 11:11 pm

A simple reliable solid piece of metal that dramatically increases airflow through the motor? Can't wait for more motors to start having these as an option!

The last two times gasoline prices spiked up, Chinese hub-motors were sold out pretty quickly. I am certain that gas prices are on an upward trend, and soon, non-hub will be the only game in town.
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Re: Fan cooled 3220s are finally here!

Postby Dirt-E-Dan » Sat Feb 04, 2012 8:36 pm

Those motors look amazing. We can't wait to attempt to push them to their limits!
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Re: Fan cooled 3220s are finally here!

Postby Sharkboat » Tue Feb 21, 2012 7:01 pm

Did you get a chance to test the 3220-F max continuous power? Max peak? Would you need a controller other than the HV160 to test it at those power levels?
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Re: Fan cooled 3220s are finally here!

Postby liveforphysics » Tue Feb 21, 2012 7:19 pm

Looks like you're approaching the cooling abilities of an out-runner now. That's a big step up! Good work!
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Re: Fan cooled 3220s are finally here!

Postby recumpence » Wed Feb 22, 2012 8:39 am

I have not tested the continuous power levels for a couple of reasons. However, the airflow is decent through the motor and they run much cooler than without the fan cooling (obviously). There are a couple cool developments I have in the works that will take this cooling idea even further. I am pushing for the absolute ultimate cooling ability possible! I have looked into liquid cooling (I have much experience in this from liquid cooling car audio amplifiers in my past), but I am not going that route for many reasons, not the least of which is added complexity and considerable added cost. These motors cost enough as it is. However, I believe I have a design that will perform every bit as well as liquid cooling. Basically, I am taking the air cooling to the logical limit, per Motomoto's cooling design with his help, as well as taking the "Pulling heat out of the housing" idea that my DaVinci drive uses to the limit as well. I am pushing for the absolute ultimate high output motor from this size factor that can be achieved. I am also making it as good looking as possible. I find no good reason to make something ugly, just for performance reasons. I mean, don't get me wrong, performance (especially in racing) is the most important thing. However, when starting from scratch with a blank piece of paper on the design and having complete control over how it is done, why not make it look insane as well as perform at the limit? :mrgreen:

Anyway, yes, a 160 is fine to run this motor. That is mainly because the 160 is already running well at high power levels (as long as the throttle setting is high, such as in racing or Pike's Peak climbing). It is the motors that are having heat problems now (hence the fan cooling). What I am trying to accomplish is a true power output of 7,000 minimum, preferably 8,000 watt continuous power handling. When I say continuous, I mean continuous, as in endless. Judging by the results of various cooling experiments we have done so far, this looks not only doable, but surpassable. The 160 is fine with this output assuming it is above 60 or 70% throttle setting for the majority of high output running. I see no reason why it would not be if being pushed so hard.

I hope to see a few of these new motors in a few race bikes this year being put through their paces. :wink:

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Re: Fan cooled 3220s are finally here!

Postby kevo » Wed Feb 22, 2012 10:47 am

Any chance of this design 'trickling down' in the future to the 3210's for those who use lower power?
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