12 kw rc motor

[SplinterOz]

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

Stock 72volt 500amp(peak) controller this controller would not drive this motor anywhere to its peak if you put on water cooling.

The biggest thing toolman2 and I did was be really careful with the hall sensor position in the motor. In the prototypes the halls are glued between the stator teeth by hand and with hot glue. (NOTE the production model does not have this design). From the factory one of our sensors was out by 25 degrees or so. We corrected this electronically using Burties Timing adjuster, and later physically by re-gluing it.

When we did stress tests and the motor heated up the glue softened and the halls moved again. We then cleared all the hot glue and then used High Temp glue and some mounting wedges to ensure all of the halls were within a few degrees of perfect. Once the halls were perfect the controllers had no issue under load or at speed.

[Jay64]

That is a cool build Splinter.

[modern_messiah]

Really quick question for anyone who would be kind enough to answer me - but what is the thickness of the can used on these motors and what size are the magnets?

Curious is all...

[Arlo1]

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

Sorry i just saw this.... Yes i have but the goal is to get more inductance in the motor!

[Arlo1]

I pulled my wire from 7:30am to 1:30pm today and man my hand hurts! I even used a glove!

[fizzit]

You wound that with your bare hands and absolutely no tools?

[Arlo1]

You wound that with your bare hands and absolutely no tools?

I had a couple popsicle sticks and a glove to hold the wire with.

[fizzit]

So did you wind by holding onto the wire itself or by holding onto the spool of wire? I'm just wondering because many people complain about their hands hurting after rewinding, and I'm trying to figure out if they are doing it by just pulling on the bare wire with their hands. I couldn't get that to work for me.

[Arlo1]

So did you wind by holding onto the wire itself or by holding onto the spool of wire? I'm just wondering because many people complain about their hands hurting after rewinding, and I'm trying to figure out if they are doing it by just pulling on the bare wire with their hands. I couldn't get that to work for me.

I wraped some extra lengh of the wire around an un used tooth then I held the stator on the bench with one hand and pulled the wire with my other hand and the side I was pulling was on the spool, thud likes to clamp the stator in a vice but I like to be able to spin the stator to make the turns faster!

[markobetti]

I pulled my wire from 7:30am to 1:30pm today and man my hand hurts! I even used a glove!

wow,, nice work .....wow.....

[Arlo1]

Thanks Marko. I think when I do the other one I will try 13awg with 8 turns a tooth. This is 8 turns of 14 awg. I went with 8 turns a tooth then run the wires from each half out of the motor. So now I have A+ #1 and A- #1 B+ #1 and B- #1 C+ and #1 C- #1 All from one side. Then A+ #2 and A- #2 B+ #2 and B- #2 C+ and #2 C- #2 From the other Half the stator. For now I terminated them in parallel for the same 75kv we had before but I have the option for series as well with 1/2 the rpm 4 times the resistance and 4 times the inductance! I can also use two separate controllers If I want. I put two sets of Honeywell s41 halls in it as well. I will measure motor inductance today with the can on but with the can off its 18.5uH so Im guessing ~10uH with lower resistance then stock and the same KV so I made a more efficient motor which is easier on controllers!

[drewjet]

I wraped some extra lengh of the wire around an un used tooth

That must be one hell of a tooth!

I always take my wire and clamp down on it with my bench vise. That way I have my hands free to turn the stator, and can pull on the stator to tighten up the winds. You do need a pretty long path clear from your bench vise, but for me it works out great and no sore hands, plus I don't have to wear gloves which makes it easier with better finger dexterity.

[Arlo1]

So as i posted in the inductance thread "Damb i just mesured collossus with the can on and its back to were i started! 8uH in the low posistion and 11 in the hi! I cant belive its less then 50% of what it is with out the magnets! They must be strong!"

[fizzit]

I wraped some extra lengh of the wire around an un used tooth

That must be one hell of a tooth!

I always take my wire and clamp down on it with my bench vise. That way I have my hands free to turn the stator, and can pull on the stator to tighten up the winds. You do need a pretty long path clear from your bench vise, but for me it works out great and no sore hands, plus I don't have to wear gloves which makes it easier with better finger dexterity.

Ahhh I see! I clamped my stator in the vise and then took a 12" long piece of 2" pvc pipe and put a notch in the end. I then wrapped the wire around it so it came out from the middle. I was able to use this to pull hard on and bend the wire around the corners very easily and my hands never hurt. But I was curious if there was something wrong with my method, and what other people were doing.

[Arlo1]

Ok so i printed this picture. I have been trying to figure out how the best way to connect the ends of the wires.... I can't find an online calculator that shows it. Biff told me it might be best to wire it in WYE I have it connected in delta right now but looking at this picture it doesnt make sense how it will work to its max efficiency... The way I look at it is...
In delta the phase energised flows most of the power but the 2 unused phases will flow 1/2 as much at the used phase. (I need someone to correct me) So in this case there will be times when you can have all teath pushing/pulling the right direction. I used the picture to help imagine it.
Then in WYE I connected the ends of each phase and it made sense I could get it to always push/pull on all the teath that are energised!

Any insite would help! Tonight I will try connecteing in WYE if I get a chance!
This should give 4x the inductance with 1.73 times less rpm so.....

[Arlo1]

I love how 4110 mosfets are like expensive candy! I pour them out of the package into collossuses mouth and collossus is like yummmm candy give me more! One day you mother fucker I will feed you a mosfet or IGBT you will choke on!!!!

[liveforphysics]

Your winding factor doest change depending on how you terminate.

[Arlo1]

Your winding factor doest change depending on how you terminate.

I went from delta to WYE so lost 1.73 times the kv but gained 4x the inuctance. I was not looking at winding factors in delta i was trying to find a good way to terminate in delta and there is not one!

[zEEz]

Yyyykesss, Arlo ....
now i understand why you told in my other 3d to fear so much the blown 4110 ...
the motors you wind are like dead shorts for the poor controller ...
even a 360 fets infineon controller low RdsON will not suffice

have fun"!"

[zEEz]

Whoooaaa ... .. It took me several days to read carefully all the 98 pages ...
Impressive work and R&D inside there ...
Incredible the Colossus motor: I admit I'm tempted to get one exemplar of the Colossus LQC v.3
But I would like first to find some answers to few questions remaining ... :
is the v3 available for buying and at which price and where?
is the markobetti special controller around?
are the discrete double megamosfet from lfp working for the colossus?
last thought of SplinterOz and Arlo about the motor and who tested v.3?

thanks guys and have fun!

[dumbluck]

I would be interested in purchasing some also.

I would even be interested in just purchasing parts I would wind and build them myself.

any chance on getting parts?

[Arlo1]

Wait till someone has them running at hi power otherwise you are wasting your money!

[zEEz]

Wait till someone has them running at hi power otherwise you are wasting your money!

from this I deduce that nobody achieved full performance from this motor yet?

I confess I bought already a Mars ME0907 that I want to use for an e-motorbike in couple
with a 36 mosfet infineon from e-crazyman and it
looks to be a very reliable option, except that power is limited ...

On the other end, if the colossus works fine as expected, I would prefer it for motorbike use and
I would re-purpose the Mars for a future electric boat ...

have fun!

[Arlo1]

Wait till someone has them running at hi power otherwise you are wasting your money!

from this I deduce that nobody achieved full performance from this motor yet?

I confess I bought already a Mars ME0907 that I want to use for an e-motorbike in couple
with a 36 mosfet infineon from e-crazyman and it
looks to be a very reliable option, except that power is limited ...

On the other end, if the colossus works fine as expected, I would prefer it for motorbike use and
I would re-purpose the Mars for a future electric boat ...

have fun!

. No nobody makes a controlle that can make any power with this yeat!!! I started a controller build thread just because of this motor! People say they have it running but untill you see video of hi power i wont belive it! We can drive this motor with some of the controllers but only at low power if somebody makes 30 hp on a dyno i want to see video!!!

[zEEz]

No nobody makes a controlle that can make any power with this yet!!! I started a controller build thread just because of this motor!!

I read markobetti talking about a paramotor controller made specifically for the colossus ....
anybody knows anything about it?

have fun!