Search found 330 matches

by hias9
Jan 26 2022 12:14pm
Forum: EBike Technical
Topic: Maximizing Copper Fill
Replies: 34
Views: 765

Re: Maximizing Copper Fill

So you think that even 4mm bending radius would be no problem for 3mm thick rectangular wire? I think it would work but i wouldn’t use 3mm thickness. I’ve tried 2mm and that’s stiff enough for me :wink: Wire then need to be shaped with tools and levers, forget about pulling it into place. Were you ...
by hias9
Jan 25 2022 6:41pm
Forum: EBike Technical
Topic: Maximizing Copper Fill
Replies: 34
Views: 765

Re: Maximizing Copper Fill

So you think that even 4mm bending radius would be no problem for 3mm thick rectangular wire?
by hias9
Jan 23 2022 6:42pm
Forum: EBike Technical
Topic: Maximizing Copper Fill
Replies: 34
Views: 765

Re: Maximizing Copper Fill

Why should the enamel be added before shaping?
I think it makes much more sense to simply add the enamel to rectangular copper wire.
If you search for it on YouTube for example, you can see that the enamel is added to rectangular copper wire.
by hias9
Jan 23 2022 5:32pm
Forum: EBike Technical
Topic: Maximizing Copper Fill
Replies: 34
Views: 765

Re: Maximizing Copper Fill

It's not a comparison of .03mm vs .04mm The layer thicknesses are the same in both cases (only the value in parenthesis which is the minimum layer thickness at the corner is slightly different). It's a comparison of the Hitachi wire against common wire of this size. I highly doubt that it's insulate...
by hias9
Jan 23 2022 12:14pm
Forum: EBike Technical
Topic: Maximizing Copper Fill
Replies: 34
Views: 765

Re: Maximizing Copper Fill

Do you mean page 8 (the page which has two pictures on it) ? The two wires which are compared there have the same insulation thickness (only slightly different at the edges). I also found this pdf some weeks ago, but did not find any place where to buy that high reliability Hitachi wire in smaller q...
by hias9
Jan 23 2022 8:36am
Forum: EBike Technical
Topic: Maximizing Copper Fill
Replies: 34
Views: 765

Re: Maximizing Copper Fill

130kph would be 1100rpm and with 16 pole pairs it would be less than 300Hz. So I doubt that skin effect is a big issue here. Bending radius would be less than 4mm in this case. So I doubt that this would be possible with 5.5*3mm wire without damage. So you think 5.5*1 3 in parallel would be fine or ...
by hias9
Jan 22 2022 9:55am
Forum: EBike Technical
Topic: Maximizing Copper Fill
Replies: 34
Views: 765

Re: Maximizing Copper Fill

I plan to use it on a direct drive hub motor, so skin effect is not really an issue.
But because of bending radius I doubt that something like 5.5x3mm would make sense if the stator tooth width is only about 7mm. So instead I guess I would have to use 5.5x1mm 3 in parallel or 5.5x0.5mm 6 in parallel.
by hias9
Jan 21 2022 1:38pm
Forum: EBike Technical
Topic: Maximizing Copper Fill
Replies: 34
Views: 765

Re: Maximizing Copper Fill

What are your experiences about the possible bending radius when using rectangular winding wire? When rewinding a DD hub motor with 36 or 51 slots and 3 turns I would guess that using a single 5.5x3mm wire would not be possible, but one would have to use 3 5.5x1mm or even 6 5.5x0.5mm in parallel ins...
by hias9
Jan 20 2022 3:43pm
Forum: EBike Technical
Topic: MXUS 3000 Hub Motor - V1 V2 V3
Replies: 1915
Views: 89056

Re: MXUS 3000 Hub Motor - V1 V2 V3

If you only want to run it up to 100A phase current there is no need for upgraded phase wires. If its a v3 it should already have 4mm2 wires (AWG 11). With insulation the diameter is smaller than usual wires because the PTFE insulation is thinner. If you have a M16 axle, AWG 10 PTFE wires should fit...
by hias9
Jan 15 2022 11:49pm
Forum: EBike Technical
Topic: Reducing Rotor back-iron
Replies: 8
Views: 234

Re: Reducing Rotor back-iron

Did anybody here who worked with those motors that have backiron inside an aluminium shell experience rotor deformation by spoke tension? Was it just an iron ring pressed into an aluminium shell or did it have some kind of form-closure (to avoid problems with thermal expansion when the motor gets ho...
by hias9
Jan 15 2022 10:47pm
Forum: EBike Technical
Topic: Programming ASI Bac 8000
Replies: 62
Views: 11349

Re: Programming ASI Bac 8000

Allongold wrote:
Jan 15 2022 8:09pm
Hello everybody,
Wanted to go for a ride today and all of a sudden my bike won’t move. Does Anyone know what could be the issue that I don’t have a throttle? Also the bac 8000 is blinking.
Which error code is it blinking (for example 2 flashes, then 4 flashes) ?
by hias9
Jan 15 2022 10:11pm
Forum: EBike Technical
Topic: Reducing Rotor back-iron
Replies: 8
Views: 234

Re: Reducing Rotor back-iron

Why do you think the manufacturers went away from using backiron inside an aluminium shell?

Did it have some kind of form-closure or was it just an iron ring pressed into an aluminium shell?
by hias9
Jan 14 2022 10:45am
Forum: EBike Troubleshooting
Topic: DD hub Magnets rubbing Stator after adding Statorade
Replies: 27
Views: 613

Re: DD hub Magnets rubbing Stator after adding Statorade

I won't have time the next days, but I am sure the problem is not on the stator/axle part, but has to be on the rotor/sidecover part. Maybe I will then install another stator to test if the problem persists. But the axle sits firmly inside the stator core and is additionally hold in place by a circl...
by hias9
Jan 12 2022 5:05pm
Forum: EBike Troubleshooting
Topic: DD hub Magnets rubbing Stator after adding Statorade
Replies: 27
Views: 613

Re: DD hub Magnets rubbing Stator after adding Statorade

Just look what I wrote in my post right above yours one hour ago.
I always remove the side covers when adding Statorade because it will slightly leak at high rpm when not using silicone.
by hias9
Jan 12 2022 4:06pm
Forum: EBike Troubleshooting
Topic: DD hub Magnets rubbing Stator after adding Statorade
Replies: 27
Views: 613

Re: DD hub Magnets rubbing Stator after adding Statorade

At the moment unfortunately not. Well, the only thing I changed was adding the Statorade. I pressed the stator about 40mm to one side (with a 3-arm gear puller), then added the Statorade to the magnets, then slowly let the stator go back to it's final position (aligned with the magnets). The strange...
by hias9
Jan 11 2022 7:01pm
Forum: EBike Troubleshooting
Topic: DD hub Magnets rubbing Stator after adding Statorade
Replies: 27
Views: 613

Re: DD hub Magnets rubbing Stator after adding Statorade

I already tried with about 3 different sidecovers (some of them completely new) on each side and completely new bearings.
by hias9
Jan 11 2022 10:17am
Forum: EBike Troubleshooting
Topic: DD hub Magnets rubbing Stator after adding Statorade
Replies: 27
Views: 613

Re: DD hub Magnets rubbing Stator after adding Statorade

The rim is a strong DH rim and can take way more than 1100N. The stator is perpendicular to the axle and the axle is not bent. Problem is on the rotor/sidecover part, not on the stator/axle part. The problem is that the stator seems to be sitting inside the rotor like in the drawing (of course it's ...
by hias9
Jan 11 2022 9:52am
Forum: EBike Troubleshooting
Topic: DD hub Magnets rubbing Stator after adding Statorade
Replies: 27
Views: 613

Re: DD hub Magnets rubbing Stator after adding Statorade

Yes, tension was quite high. About 1100-1400N. 30% variance is not much. If you need much dishing offset, variance between the left and right side will already be higher than that. In this case there is not much variance because I don't need much dishing offset und put ellbows in on one side and ell...
by hias9
Jan 10 2022 11:00pm
Forum: EBike Troubleshooting
Topic: DD hub Magnets rubbing Stator after adding Statorade
Replies: 27
Views: 613

Re: DD hub Magnets rubbing Stator after adding Statorade

The rotor needs not only to be round (not egg shaped) but also concentric with the axle or you will quickly run into envelope issues with something like this. Not sure if you can put a dial indicator on a machined part of the rotor that parallels the magnet mounting surface to see what you now have...
by hias9
Jan 10 2022 8:55pm
Forum: EBike Troubleshooting
Topic: DD hub Magnets rubbing Stator after adding Statorade
Replies: 27
Views: 613

Re: DD hub Magnets rubbing Stator after adding Statorade

Not really. It did not change at all with trueing the rim. I trued the rim (not the rotor. If spoke tension would be exactly equal everywhere, the rim would not be trued. However spoke tension is pretty much equal at the moment) after the rubbing started (which was when I added the Statorade). If th...
by hias9
Jan 10 2022 11:43am
Forum: Battery Technology
Topic: Lipo Crash Stability
Replies: 4
Views: 273

Re: Lipo Crash Stability

When starting this topic I was sure the answer will be just build a protective case ;-) I don't plan to build a case, but to use a carbon fibre plate on the outside with foam on the inside to a absorb the energy in the event of a crash. Thank you, I will place the batteries with the sides up/down, s...
by hias9
Jan 10 2022 11:22am
Forum: EBike Troubleshooting
Topic: DD hub Magnets rubbing Stator after adding Statorade
Replies: 27
Views: 613

Re: DD hub Magnets rubbing Stator after adding Statorade

Yes, I already thought of that and trued the rim a bit. Also checked with a tensiometer. Spoke tension was quite high (I reduced it a bit now), but I am only using butted 13/14ga spokes and guess the force on the rotor would usually be higher when using 10/12ga spokes. Also there are the cooling fin...
by hias9
Jan 10 2022 2:29am
Forum: EBike Technical
Topic: Reducing Rotor back-iron
Replies: 8
Views: 234

Reducing Rotor back-iron

Can back iron on a DD outrunner be reduced to save weight without a negative effect on efficiency as long as there is still no magnetic field measurable on the outside of the ring?
by hias9
Jan 10 2022 1:05am
Forum: EBike Troubleshooting
Topic: DD hub Magnets rubbing Stator after adding Statorade
Replies: 27
Views: 613

Re: DD hub Magnets rubbing Stator after adding Statorade

By the way, what exactly is the reason why there is sometimes the stator rubbing on the magnets if reinstalling the sidecovers in a different way? How do they know at the factory in which way they need to be installed? I reinstalled them the same way like they were installed, but also have this rubb...
by hias9
Jan 10 2022 12:56am
Forum: Battery Technology
Topic: Lipo Crash Stability
Replies: 4
Views: 273

Lipo Crash Stability

When a 6S Lipo for example (without a case) hits a stone, would damage to it probably be higher when
1) it hits it with its top/bottom?
2) it hits it with its left/right side?