Adding hall sensors to outrunners

[AussieJester]

just thought I would show the pcbs that I have just made ready to be potted and fitted to two of my motors. When I am back in work I will upload the artwork should anyone wish to make them.

Hall pcb_64mm_front.jpg

hall pcb_64mm_back.jpg

Hall pcb_80mm_front.jpg

Nice work GWhy... the elongated holes are so you can adjust the plates positioning i gather.

KiM

[gwhy!]

Yes, KiM.
When I have one mounted I will post some pics.

[AussieJester]

Yes, KiM.
When I have one mounted I will post some pics.

Cheers mate...forgot to ask also, which motor is this
setup destined for?

KiM

[gwhy!]

Yes, KiM.
When I have one mounted I will post some pics.

Cheers mate...forgot to ask also, which motor is this
setup destined for?

KiM

I have one of the large Turnigy 80-100-A 180Kv (80mm can) that one set will used on, But my motors of choice is the smaller TGY AerodriveXp SK Series 63-74 170Kv (64mm can)( I like them so much I have 2 ), These already have halls fitted but the spacing of the halls isnt quite 100% ( But they do both work really well ) so I thought make it 100% correct and it will improve efficency a bit.

[Burtie]

gwhy,
This is a pretty neat looking solution for holding the sensors that simplifies the wiring nicely too.
I am keen to see how you will mount the pcb to the motor.

Great work!
Burtie

[gwhy!]

Picture's
Burtie,
This is how I intend to mount them. The pcb can be made not so tall but a bit longer so the adjusting slots can go either side of the halls. The pcbs will be potted soon which should keep all the elements out of the sensors. I will post up a picture when it is potted.

Large motor mount with halls.jpg (42.08 KiB) Viewed 840 times

Large motor mount with halls gen2.jpg (45.16 KiB) Viewed 840 times

Large motor mount with halls size.jpg (39.38 KiB) Viewed 840 times

Large motor mount with halls size2.jpg (34.11 KiB) Viewed 840 times

Sorry for the blurriness of the pics, I must sort out a better camera phone.

[dontsendbubbamail]

Thought I would post how I mounted my hall effects along with the other methods in this thread. This is just three 1/2" plywood rings with a 1/4" cover ring.

Bubba

Two rings glued together. Top ring has 1/8" grove for wiring. This will be covered with a 1/4" ring. Notches were included for 60 or 120 deg spacing.

file1.jpeg (155.03 KiB) Viewed 873 times

Side view of two rings glued together.

file2.jpeg (111.35 KiB) Viewed 870 times

Gluing hall effects.

file3.jpeg (127.62 KiB) Viewed 873 times

Hall effects glued in place with 120 deg spacing, wired up, and ready for the cover ring.

file4.jpeg (186.88 KiB) Viewed 870 times

Cover ring glued in place

file5.jpeg (95.59 KiB) Viewed 870 times

Bottom ring of the previous rings slip into this ring.

file6.jpeg (94.21 KiB) Viewed 819 times

file7.jpeg (98.1 KiB) Viewed 819 times

[gwhy!]

Hall sensor pcb artwork as promised. Its not the neatest artwork but it works

pcb_halls_.cad- CadStd.pdf

(60.06 KiB) Downloaded 166 times

[gwhy!]

Some pics of hall sensors 'now potted'

64mm potted sensor

halls potted.jpg (41.35 KiB) Viewed 758 times

80mm potted fitted sensor

halls potted fitted.jpg (56.53 KiB) Viewed 758 times

[gwhy!]

I just fitted one of these to smaller motor ( 64mm can ) and its made quite a difference, my previous hall sensors where slightly of with spacing but I could get my motor to a unloaded current of about 2.5A @48v and on the bike it worked well. But know .. what a difference unloaded current of 2A @48v and the starting torque has gone through the roof Im well chuffed

[dbaker]

Gwhy?

What was your best unloaded current (input to controller) at what measured voltage for the larger 80mm motor? I just got external sensors fitted using your template for the large Turnigy HXT (C80100-130) and saw 5.9 amps at 53 volts WOT with a 12 FET Keywin controller. That is about 300 watts and the motor windings got up to 120 F. How touchy was your adjustment? I guess when we first set up the brackets it is random as to where the sensors are relative to the windings. Adjustment should find the current minimum somewhere along the adjustment range.

Thanks for your pioneering work here!

Dave

[gwhy!]

Gwhy?

What was your best unloaded current (input to controller) at what measured voltage for the larger 80mm motor? I just got external sensors fitted using your template for the large Turnigy HXT (C80100-130) and saw 5.9 amps at 53 volts WOT with a 12 FET Keywin controller. That is about 300 watts and the motor windings got up to 120 F. How touchy was your adjustment? I guess when we first set up the brackets it is random as to where the sensors are relative to the windings. Adjustment should find the current minimum somewhere along the adjustment range.

Thanks for your pioneering work here!

Dave

Hi Dave the lowest WOT no-load current for my large motor was around 5.5A @48v this was after I removed the skirt bearing ( which sucked an additional 1A !) I would say your not far off with your setting as it is . Yes you adjust the sensors position until you get the lowest current, The best way I found to do this is adjust the position of the sensors while you are running the motor and keep a eye on the current meter, but just have the motor ticking over not WOT. I spent quite a bit of time trying to find out if this was "normal no-load current" for these big motors because this was my main concern about how hot it would get but it would appear to be normal from what other people have said and from the tests I carried out I couldn't find anything wrong with my motor except the skirt bearing was shot from new. If its the newer type of motor that you have i.e with the skirt bearing what I found helped to get a better thermal path to the out side world was to put some thermal grease between the matting surfaces between the the parts on re-assemble ( I wish I took some pics of this because its hard for me to describe ).

[dbaker]

Thought I would post how I mounted my hall effects along with the other methods in this thread. This is just three 1/2" plywood rings with a 1/4" cover ring.

Bubba

file1.jpeg

file2.jpeg

file3.jpeg

file4.jpeg

file5.jpeg

file6.jpeg

file7.jpeg

Bubba,

What was WOT unloaded current and voltage for you witht he HXT motor?

Thanks,

Dave

[toolman2]

ive got some halls mounted up inside the big turnigy "130 kv" motor, and its now running well.
no luck as yet with them outside -allways noisy or maby interference from the coils magnetic field, hopefully the photos come up to show it.

i changed the motor to Y from delta so it matches to voltage and currents the most controllers and packs are running, and i expected lower idle (circulating) currents for the same rpm -it worked out about the same though. but the motor should now be about 75kv.

so after much pissing about, i got it to run smooth on halls with a 12fet infinion, took ages to tune the exact individual hall positions for precise matching of each phase emf by running the motor with a drill -ie 0 deg timing, the hall traces are dead clean at all rpms and all exactly 120 deg apart, it ran smooth at 75kv (2900rpm 1.79A 39v), and can tick over at super low speed useing only 1.5w!
BUT this was not the best setting, with the timing advanced lots, the rpm went up to 3500 (using 2.9a) so this is nearly 90kv, or 155kv! (in original delta).

at this advance the motor had noticeably less torque at low rpm and the extra current draw is not cool. then i ran it on 79.6volts and this advanced setting (at 6500rpm) was acctually the lowest current draw, (a bit up and down?) but not that good at crawling speed. and now (6000+rpm) at 0 deg timing the sound is harsh and the draw higher.

so we now have a very narrow window for optimum timing to cover all rpm ranges, but the zip folder has this final setting on the cro compared to 0 deg setting. set for the best compromise -careing mainly for a low idle current, now the motor spins at 6300rpm at 79.6v and 2.51a so its 79kv (or 137kv delta) at about 200w used idleing its as low as i can get it and toward the max rpm for this motor without wads of extra heat and losses.

the formulas now show peak efficiency of 94% at 82a, 6527w in 6136w out with 200w (idle) + 200w (ir) -about 10Nm at 6000rpm.
so much torque and smooth crawling ability, now bolting to bike..

[AussieJester]

Excellent work mate haven't been game to try myself as yet waiting for spare motor so i can have a play without messing with the running bike.

Would you be open to accepting $$$ for converting Outrunners with halls maybe? If so what would you charge?
I couldn't be so lucky that your in Australia could i haha...well done anywayz mate.

KiM

[Burtie]

Nice work toolman,

I like the way you can adjust the timing with this internal arrangement .

On your 'scope pictures, where did you connect the probes to measure the back EMF, accross 1 isolated phase or between two phases with the motor connected in wye?

It is tricky to see in the picture, but it looks like you are using the 17.1 degree mechanical spacing between the sensors, and that it is fitted to the version of the motor without the skirt bearing?

Is it an easy task to separate the winding terminations and convert the motor from delta to wye?

Sorry for so many questions, -but this is good stuff!!

Burtie

[Burtie]

KiM
Dont be afraid of fitting hall sensors to your motor. If you dont mind just glueing them in the stator slots, which works well on my Stinky, it would be a very easy job for you to do (considering some of the amazing stuff I have seen you produce in the past )

You usually need to take these Turigy motors apart to fix the bearings anyway!

Go for it.
Burtie

[toolman2]

Excellent work mate haven't been game to try myself as yet waiting for spare motor so i can have a play without messing with the running bike.

Would you be open to accepting $$$ for converting Outrunners with halls maybe? If so what would you charge?
I couldn't be so lucky that your in Australia could i haha...well done anywayz mate.

KiM

yep , i am in oz (canberra unfortunately) and could help you get halls sorted, so maby if you post up a photo of yourself wearing i nice big frock, then ill see what i can do..
-jeez you do meet some weirdos on the internets.


all fair questions burtie,
the scope setup: you hook ch1 signal to a hall colour (say blue) and earth to the common hall blacks. ch2 sig to the blue phase wire and its earth to the green phase wire.

i usually use the controller (still hooked up) to power and load the halls in the normal way, but DONT hook up the controller phases to anything or it all gets i bit smoky (ask me how i know) as the scopes earth's are linked.
it sounds tricky but its not, the phases are now just floating.

you then do the same for say the green hall (ch1) and ch2 sig to the green phase and earth to the yellow phase
and then.........................the yellow hall (ch1) and ch2 sig to the yellow phase and earth to the blue phase.

-might sound odd but it becomes simple cos then all you are looking for is a dead match (in direction and position) between each hall and its (same colour) phase, this would be 0 degrees timing, the motor will then run the same forward or reverse with any normal controller, and most hub motors seem close enough to this standard.

the need for more advance than this (all shown in the zip file a few posts back) is prolly cos of such high rpm, and is maby correcting for lag in the controller or something??

my halls ended up 10.205 mm apart centre to centre and they are 1 or 2mm inboard of the magnets diameter -how many degrees? , and yep its an early non skirt bearing motor.

it was a bit of pain to separate the windings but they didnt need to be cut, but it seems worthwhile cos now it is usable with higher voltage battery packs and normal 12 fet controllers now have a better chance (1.73 times better) of getting torque out of the motor.
when i ran it in delta it was just to hard on the controller and i was stuck haveing to run over 12 4110 fets and under a 50v pack -in summary the controller get hot and the motor didnt!

[dbaker]

Excellent work, Toolman2! So we now have a benchmark for setting up the large HXT's. It looks like you used some perfboard to mount your Halls? In your opinion do we need to do the winding separation to use the HXT's with the 12 fet controllers?

Dave

[SilverSurfer]

Thanks for all the hard work you guys! SS

[gwhy!]

Im am going to make myself some hall sensors as spares for my 64mm and 80mm motors the same as I have made before, as I am making the pcb's I was wondering if anyone would also want one ( as its not to much trouble to make additional ones ) I only have enough hall sensors for my 2 spares but I would order some more halls if enough people want a complete sensor for there motors ( potted and tested with fly leads), the pcb's will be shaped and drilled ready to be assembled if you would like just the board. If anyone is interested please PM me with your requirements. pcbs will be £3.00 uk pounds
+PP, a fully assembed, potted and tested sensor will be £25.00 uk pounds +pp.

Pic of hall sensor as a reminder:

Hall pcb_64mm_80mm.jpg (49.53 KiB) Viewed 966 times

halls potted.jpg (41.35 KiB) Viewed 966 times

[swbluto]

Im am going to make myself some hall sensors as spares for my 64mm and 80mm motors the... If anyone is interested please PM me with your requirements. pcbs will be £3.00 uk pounds
+PP, a fully assembed, potted and tested sensor will be £25.00 uk pounds +pp.

So the 80mm would work for the 80-100 130kV HXT motor? Yes, I noticed the 80, I just want to make sure you're referring to the left number and not the right one.

[gwhy!]

yes this is the dia of the cans, the bigger motors are 80mm

[toolman2]

Excellent work, Toolman2! So we now have a benchmark for setting up the large HXT's. It looks like you used some perfboard to mount your Halls? In your opinion do we need to do the winding separation to use the HXT's with the 12 fet controllers?

Dave

yep it just the grid pattern board with single row traces.

i have the bike running now with 11.25: 1 gearing and 60v (loaded) pack, and a std 4310? 12 fet ecrazyman controller set at 35a limit.
-it goes well, about 52kph on a flat and it accelerates smoothly (with a bit of chain chatter) from a standing start, i cranked the current limit to about 50a
so theres about 3000w in, now it feels better and the motor is now getting warm to hot, and its toward the safe sustained maximum for this 12 fet controller.

so i put it along side the most efficient/torquey 6kg hub motored bike ive come across (and its also running 3000w in) and it won the 100meter uphill race (0 to 42kph odd) by 2 bike lengths, i had to drop the shunt (on the 80-100 130kV HXT motor) to about 2500w input and then they are both nearly equal!

in fact the average power used was 2565w for the hub motor and 2102w for the 80-100 to give identical acceleration and output for the run. the interesting difference is off the line where the hub motor pulls 3000w and (at under 5kph) over 2000w of this is going to heat, the 80-100 is different.. it only pulls about 1400w and i dont think any more than 500w is going to heat. -it (well the controller) off the line self limits to around 100a phase current because the motor resistance is so low, so it really cant (yet) press the motor into its inefficient zone.

-btw this self limiting (well below that of the actual set current) issue was a way bigger problem in delta, this helps tell us that you really do want the motor in star unless you have a 150a+ controller.

put simply the resistance is 8 times less than a "comparable" hub motor so off the line there's 8 times less heat (loss), anyway i spose im preaching to the converted here.. but its all looking good for a 1.3kg motor after its suprise win yesterday!

it would be good to hear from luke and others about how much real world continuous power these rc motors can take -my guess like any motor it may be able to do 3 times this (say 9kw) for a burst or running at light load and high rpm, but maby closer to 3kw in an ev that has massive start loads, long hills and not much cooling etc? let me know your thoughts people?

[swbluto]

it would be good to hear from luke and others about how much real world continuous power these rc motors can take -my guess like any motor it may be able to do 3 times this (say 9kw) for a burst or running at light load and high rpm, but maby closer to 3kw in an ev that has massive start loads, long hills and not much cooling etc? let me know your thoughts people?

I was doing some calculations and the motor shouldn't be making more motor than 400 watts of heat when going up a 10% incline with 250 pounds with a 20 inch wheel and a gear ratio of 12 and that's when it's putting out nearly 3000 watts or so to sustain 30-35 mph, so when properly geared, I don't think heat should be a problem with hill climbing. If it is, just gear it down even more or reduce throttle (If the controller goes into the partial throttle zone, more heat will generated by the controller due to switching losses, but it should be ok with a good ebike controller.).