Keyne's DH Comp Build - now with liquid cooled HX35! :)

[adrian_sm]

Outstanding effort. Well done.

[Spicerack]

Awesome, well done. Just a thought- if you were concerned about the corrosion aspect, you could run a thin mineral oil instead of coolant- maybe automatic transmission fluid or a very thin machine oil....

[full-throttle]

Wow! Looks really good!

How's the pipe attaches to the stator? Does it go around once or twice?

[crusoe]

Note the carbon fiber inserts which when epoxied in to the stamped stator form a cooling channel

Did you build those inserts from scratch? And how exactly did you get them in there?

[Doctorbass]

NIIIIICE !!!!

Awsome!... you did what many of us would like to !

Hal already did that, Lowracer too i think. and now you are the third...

but you are the first to share INTERESTING data !!

Thanks for all effort!!

Doc

[kfong]

Very creative with the carbon insert and milling out the motor to reduce the unsprung weight. A very well thought out design. Probably one of the first to be successful on ES at making one. Makes me actually rethink my thought on bigger hubbies for my DH build, if I get tired of the BMC.

[French]

Very cool!!! (pun intended)

[dnmun]

so elegant. if they could build the stator from the beginning with the cooling channel underneath the two plates they rivet together, or make it somehow integral before they put the steel laminations on, then i would be straightforward to water cool. exiting the side with the new plate was essential, well done.

[E-bike4life]

EVboner Very nice build. Keeps getting better and better. Thanks for the solutions with pics.

internal1.jpg (61.92 KiB) Viewed 980 times

[veloman]

A radiator on an ebike.... fuukin A!

Nice job!

[keyne]

Wow! Looks really good!

How's the pipe attaches to the stator? Does it go around once or twice?

It goes round twice. Which pipe do you mean? Basically everything is epoxied in place, pipes are held down with cable ties.

[keyne]

cable_exit.jpg (60.59 KiB) Viewed 783 times

There are 4 holes for the cables, I hadn't drilled them in the earlier photo. ( not pushed onto the axel fully) Note that even though it is a standard rotor, it did need to be ground down for clearance - could be done without, but I made a few mistakes.

carbon-insert.jpg (62.4 KiB) Viewed 783 times

This is a failed carbon insert, just a band on a funny angle to make a pipe like cavity when put into the stamped stator.

pipe_exit.jpg (27.55 KiB) Viewed 783 times

This is one attempt at making the exit pipe, gives you the idea.

[Trackman417]

Well IM JEALOUS! When I get something nice and expensive I'm surprised I have the balls to even look at it let alone use it lol. and here you are modding things like a BOSS!
haha gotta love that smiley
Glad the radiator works! Have fun

[rojitor]

This thread is very interesting, it's a pity i didn't find it earlier.subscribed.

[sn0wchyld]

are you running the coolant on both sides of the motor, or just the side we can see in the pics?

this build just gets better and better. cant wait to see the CF covers!!

[full-throttle]

It goes round twice. Which pipe do you mean? Basically everything is epoxied in place, pipes are held down with cable ties.

The heat exchanger on the stator. So it makes 2 turns, right? Trying to picture the contact area.. Is it on both sides of the stamped stator?

Just looked through your posts and emails - the water-cooling project started in April last year!

[keyne]

I'll post some cad drawings to make it clear - both sides of the stator are used, it's really basic - you'll see.

Yeah, not the quickest development time

[Alan B]

Liquid cooling - the next level.

[amberwolf]

This is a pretty nifty bit of your project there!

I may borrow bits of this for my powerchair motor project,
viewtopic.php?f=30&t=32838
if I find it gets more than warm during use. I have a PC water cooling radiator system laying around, includng it's pump and whatnot, and a bunch of other fittings, so I might be able to use only what I already have to do it.

Hopefully I won't need to...but I intend to try using this motor for a Death Race or similar eventually, and I don't expect it to stay very cool for that without some help.

[keyne]

cad2.JPG (26.16 KiB) Viewed 694 times

should make things clearer

cad1.JPG (27.73 KiB) Viewed 687 times

Blue is carbon inserts, black is steel stator, gold is copper

[keyne]

I asked questions about this project in April '11 here: http://endless-sphere.com/forums/viewtopic.php?f=2&t=24593&start=285#p387751 but no one was interested.

To answer my own questions, yes that is reasonably well thermally coupled and yes the hall wires can be put through the windings Now I just need a time machine...

[Hyena]

Awesome work Keyne! All the milling work on the outside of the hub was impressive enough until I kept scrolling down and saw the results of the water cooling. How long is the motor pulling that sort of current up the hills you're riding ? 1 minute ? 5 ? 10 ? Either way I guess the proof is that it runs much cooler doing runs that would get it significantly hotter.
Looking forward to the results of more tests.

[GCinDC]

Yeah, like that's really nice and all, but you can't just be making one for yourself anymore... You gotta start up an assembly line and distribution center...

Just kidding. Epic!

[BlackArrow]

Hi Keyne,

Nice work, I'm actually thinking doing the same thing with my 9C 2805, light motor with cooling can be really nice for me and allot of potential for many people here, Thx for sharing it

Good day!
Black Arrow

[keyne]

Liquid cooling - the next level.

Yeah, air cooling just didn't cut it - I have a lot of sand around on the tracks where I live and I don't like having to baby it. When you think about it the thermal path in a standard hub motor is just ridiculous, if you were trying to thermally insulate the windings from the outside you couldn't do a much better job

I may borrow bits of this for my powerchair motor project,
http://www.endless-sphere.com/forums/vi ... 30&t=32838
if I find it gets more than warm during use. I have a PC water cooling radiator system laying around, includng it's pump and whatnot, and a bunch of other fittings, so I might be able to use only what I already have to do it.

You're welcome to, not too hard to do, just a bit of time required.

Awesome work Keyne! All the milling work on the outside of the hub was impressive enough until I kept scrolling down and saw the results of the water cooling. How long is the motor pulling that sort of current up the hills you're riding ? 1 minute ? 5 ? 10 ? Either way I guess the proof is that it runs much cooler doing runs that would get it significantly hotter.
Looking forward to the results of more tests.

Thanks! The tests I did on my 'favourite' hill were only about 2-3mins of gravel, 15-20% grade uphill each time. It was kind of representative of the hardest riding that I would usually do. I'll do some better testing next time I'm in the same place as my bike I have the NZ equivalent of pikes peak lined up!
If it doesn't stand up to longer hills I can just add in a coolant reservoir It means I am able to add or remove thermal mass from the system as I like.

Yeah, like that's really nice and all, but you can't just be making one for yourself anymore... You gotta start up an assembly line and distribution center...

Just kidding. Epic!

Give me a few months Just a matter of a PhD to finish, a new house to move into, and a workshop to fit out, then we can chat

Hi Keyne,

Nice work, I'm actually thinking doing the same thing with my 9C 2805, light motor with cooling can be really nice for me and allot of potential for many people here, Thx for sharing it

Good day!
Black Arrow

Yeah, a 9c is a great motor, the cooling channel would be a bit more complicated as it has bits that stick up in the stator, but would be great for a light weight option. I remember working out that it could be made to be sub 5kg Only problem is that people who want to bother with liquid cooling would want a more powerful motor to start with - maybe a HI40? What do you say Hyena?