12 kw rc motor

[Arlo1]

Im not done finding all the power a 24fet controller can make but here is a good comparison of burties board

[Arlo1]

You can multiply the torque by 5.43 for rear wheel torque!
Im actualy at the limits of this dyno so now I will get back on finishing the big dyno

[SplinterOz]

Im not done finding all the power a 24fet controller can make but here is a good comparison of burties board

Arlo1,

great work... is looking really good. You are getting up towards the torque levels we were getting. Should be heaps of fun on your little bike.

[ptd]

sorry if this is a little OT, but since these guys seem open to alternatives, does anyone think it's possible for them to make a 1/8 (or maybe 1/12) length stator, and then a 1kw motor ?

[SplinterOz]

sorry if this is a little OT, but since these guys seem open to alternatives, does anyone think it's possible for them to make a 1/8 (or maybe 1/12) length stator, and then a 1kw motor ?

The guys did build a smaller version... viewtopic.php?f=31&t=20292
Note sure if it is still available.

hope that helps

[Arlo1]

Im not done finding all the power a 24fet controller can make but here is a good comparison of burties board


Arlo1,

great work... is looking really good. You are getting up towards the torque levels we were getting. Should be heaps of fun on your little bike.

Yeh that's. 114 nm or 82 ft/lbs At the wheel and > 28.5nm or 20.52 ft/lbs plus losses of the chain and tire at the motor.

[SplinterOz]

Ok so after repositioning the Halls and checking them we redid the heat soak test today.

140 degrees C on the motor
Just under 80 degrees on the controller
120amps on the phase wires (all now withing 5 amps of each other)

So that means around 15nM continuous from this motor. Note that is with ZERO cooling! no airflow nothing. We should be able to double that with cooling.

[Arlo1]

Ok so after repositioning the Halls and checking them we redid the heat soak test today.

140 degrees C on the motor
Just under 80 degrees on the controller
120amps on the phase wires (all now withing 5 amps of each other)

So that means around 15nM continuous from this motor. Note that is with ZERO cooling! no airflow nothing. We should be able to double that with cooling.

I wouldnt expect the controller to get to hot till there is a real load on it. What are you loading it down with?

[Nuts&Volts]

I may be mistaken, but I think he is loading it with a lathe.

[Arlo1]

OK so I typed up an whole long reply to this thread and it got lost.....
Here is some inductance tests. collossus vs X5 vs HS35 stator.

[Arlo1]

Here is a chart bigmoose set up so I can add motor A,B,C and Motor A is collossus what I mesured for resistance and inductance. Motor B is adding some inductance to each phase to get a total of 40uH and motor C is a total of 60uH in each phase so... I will experiment with different windings to make as much internal inductance as possible. But you can see with a 24 fet controller it takes around 20-25 u-seconds for it to be game over for your fets! And at 95 u-seconds you are at a Kilo amp!!!

[SplinterOz]

I may be mistaken, but I think he is loading it with a lathe.

You are not mistaken. We are driving a commercial lathe with the motor mounted in the chuck. The motor is driving through the gearbox into the 2kw 3 phase motor that normally drives the lathe. This motor is turning the lathe with the gearing set to the point where it is extremely difficult to turn the chuck by hand.

I can assure you there is significant load on this motor. This should be the hardest thing this motor will ever have to do.

[SplinterOz]

Here is a chart bigmoose set up so I can add motor A,B,C and Motor A is collossus what I mesured for resistance and inductance. Motor B is adding some inductance to each phase to get a total of 40uH and motor C is a total of 60uH in each phase so... I will experiment with different windings to make as much internal inductance as possible. But you can see with a 24 fet controller it takes around 20-25 u-seconds for it to be game over for your fets! And at 95 u-seconds you are at a Kilo amp!!!

Man nice measurements... the electrical engineer dudes here will love it.

[Arlo1]

Man nice measurements... the electrical engineer dudes here will love it.

I'm trying to be as accurate as possible with the limited knowledge and limited funds for hi end test equipment. But.... Collossus is a hard motor to run and I will find a good way to wind it to give it as much inductance and the lowest resistance possible. This will make an efficient motor. Inductance is not bad it slows down the current ramp up but the energy is still there. Resistance will just waste energy into heat!

[SplinterOz]

Ok my turn... very messy setup for a test ride of the motor and gearing setup...

[EBJ]

Awesome!
Good thing you didn't fall off running the kelly input. Must be strange riding a bike like that.
This thing sounds great!

[SplinterOz]

Awesome!
Good thing you didn't fall off running the kelly input. Must be strange riding a bike like that.
This thing sounds great!

First thing today wire up the real throttle. I was not game to put to much throttle in due to the "strange" control. I kept taking my right hand down to turn the throttle... however that hand I need for braking

[EBJ]

Awesome!
Good thing you didn't fall off running the kelly input. Must be strange riding a bike like that.
This thing sounds great!

First thing today wire up the real throttle. I was not game to put to much throttle in due to the "strange" control. I kept taking my right hand down to turn the throttle... however that hand I need for braking

Hey, at least you didn't twist the pot, do a wheelie, fly off the back, and have your bike full-throttle into something.
Funny how that's all I was thinking about after seeing the "test controls"... I imagine you were thinking that the whole time as well (likely the reason it didn't happen).

[SplinterOz]

Awesome!
Good thing you didn't fall off running the kelly input. Must be strange riding a bike like that.
This thing sounds great!

First thing today wire up the real throttle. I was not game to put to much throttle in due to the "strange" control. I kept taking my right hand down to turn the throttle... however that hand I need for braking

Hey, at least you didn't twist the pot, do a wheelie, fly off the back, and have your bike full-throttle into something.
Funny how that's all I was thinking about after seeing the "test controls"... I imagine you were thinking that the whole time as well (likely the reason it didn't happen).

I thought it and was really careful.
Real throttle ride:

[AussieJester]

Great work Splinter man Seems to have adequate acceleration for a commuter bike
too! lil more tweaking and i think you will have a great setup ...Good to finally
see one of these motors in an actual bike not just spun up on a bench
and analysed to death LoL..

KiM

[SplinterOz]

Great work Splinter man Seems to have adequate acceleration for a commuter bike
too! lil more tweaking and i think you will have a great setup ...Good to finally
see one of these motors in an actual bike not just spun up on a bench
and analysed to death LoL..

KiM

Kim,
Thanks yep the acceleration is probably postie bike speed at the moment. That is with 60% motor current set in the controller and a ratio rigged to give up to about 140km/h.
I think I will go up a few teeth on the rear and then up the amps and see how it goes.

I am LOVING the fact it is now running on the bike... and once I have my headway pack setup I should really be able to push it.

[dumbluck]

looking good
is this motor your using available still and if so where can I get one?

[tostino]

Oh man, looking nice Splinter!
I've tried to catch up on what Arlo and you have been up to lately, and it's looking good!

I ordered a timing board from Burtie yesterday for use with my future motorcycle build, because that seems so necessary with this motor. Eh, I really need to get the fet cooling setup sorted for my dual 36 fet controllers that I want to use for this motor (my plan is to split each of the phases in half, and have each 36 fet drive only half of the windings (also do this inside the motor where it is wye terminated)).

I wish you luck with everything, and hope to learn from what you do so hopefully I can complete my project with the limited funds I have.

[Zen_Shenron]

Is that a stock Kelly controller you are using Splinter, or has it been "beefed up"?

[johnrobholmes]

Arlo,

Have you chased the idea of having an inductive coil with removable steel core yet? I saw it mentioned previously. If you braided the phase wires and wound them around a plastic pipe it would allow for core removal that affected each phase rather equally. Control the core with a manual lever and you could have boost