Search found 22 matches

by stepus
Apr 09 2021 6:12am
Forum: Motor Technology
Topic: Water cooled car alternator
Replies: 28
Views: 1152

Re: Water cooled car alternator

Hi, Combinations seems OK, so i am thinging about your sensor wheel, on photos it doesnt look like tooth and space between tooth are equal wide, and on video with leds, it seems to me that some leds at start of tooth is not fully light up, Do you have schematic of that IR Gate PCB ? do you have ther...
by stepus
Apr 08 2021 3:26am
Forum: Motor Technology
Topic: Water cooled car alternator
Replies: 28
Views: 1152

Re: Water cooled car alternator

in video motor sounds like its having bad timing, its running hard. Did you tried to adjust timing ? Can you do this test with sensors to we will be 100% sure they are good ? Put some LEDs with resistors on sensors output and ground, and leds should light in these order like in table Hall sensors &q...
by stepus
Apr 07 2021 7:09am
Forum: Motor Technology
Topic: Water cooled car alternator
Replies: 28
Views: 1152

Re: Water cooled car alternator

can you supply to rotor less current ? like 1-2Amps ? it can be this, alternator have also cogging effect when you power too much rotor, so controller must deliver bigger current for startup to overcome cogging. If you have right pole number sensor and alternator, and right angle between that photoc...
by stepus
Apr 07 2021 5:43am
Forum: Motor Technology
Topic: Water cooled car alternator
Replies: 28
Views: 1152

Re: Water cooled car alternator

how much amps do you delivering to rotor ? Did you tried to rotate a littlebit that pcb mounted on rotor shaft? like 2degree clockwise and anticlockwise above rotor position? When i setting timing i find position when it runs, and then run it at constant PWM dutycycle, and measuring current to contr...
by stepus
Apr 06 2021 3:07am
Forum: Motor Technology
Topic: Water cooled car alternator
Replies: 28
Views: 1152

Re: Water cooled car alternator

Hi, what is your problem with sensors ? on scope photo i can see a perfect timing phase-sensor, so what is problem ? controller cannot spinup motor ?
by stepus
Apr 03 2021 3:56am
Forum: Motor Technology
Topic: Water cooled car alternator
Replies: 28
Views: 1152

Re: Water cooled car alternator

yes 45W of additional power for motor isnt much compare to 10kW of power to windings :D but in lower power its significant percentage of power input, that rotor with magnets do not have. So this "motor" is unefficient at power like <500W and as you mentioned there can be another benefit wi...
by stepus
Mar 29 2021 11:55am
Forum: Motor Technology
Topic: Water cooled car alternator
Replies: 28
Views: 1152

Re: Water cooled car alternator

Hi, a little update with some info. I have 3d printed adapter for hall sensor PCB - using them on all my alternator conversions, luckily they have same pole number, Its from PC CD/DVD drive motor, so i salvaged them, and i can easy adjust timing/angle with rotating Hall PCB. Usualy i adjust timing t...
by stepus
Mar 11 2021 3:55am
Forum: Motor Technology
Topic: Hub motor stop working
Replies: 5
Views: 174

Re: Hub motor stop working

did you overheat motor ? it also can be shorted windings, or magnets losts force due to temperatures... can you try measure BEMF ?
can you measure resistance of all phases to stator (if its isolated), does have motor cogging efect ?
by stepus
Mar 10 2021 3:46am
Forum: Motor Technology
Topic: Hub motor stop working
Replies: 5
Views: 174

Re: Hub motor stop working

Hi,
Looks like missing one phase, it can be internal problem of controller, when you push it does it start running badly ?
by stepus
Mar 06 2021 7:10pm
Forum: Motor Technology
Topic: 10kW BLDC motor controller up to 90V and 200A with sensorless FOC - build thread
Replies: 53
Views: 1690

Re: 10kW BLDC motor controller up to 90V and 200A with sensorless FOC - build thread

if you want to mount fets horizontaly you can do it as me in my old controller. THT fets will have always problems with ringing, because they have long legs, and only one bond wire inside them. Better are SMD fets, they have more source legs - can be driven kelvin source, or better some packages hav...
by stepus
Feb 26 2021 4:26am
Forum: Motor Technology
Topic: HESC V1 150v 600Amp VESC based motor controller
Replies: 24
Views: 1384

Re: HESC V1 150v 600Amp VESC based motor controller

major inductance problem is in legs of package and bond wire in fet, so its a reason why powerfull controllers use so many fets in paralel, to lower amps by fet -> lower inductance spikes on them.
by stepus
Feb 24 2021 2:16am
Forum: Motor Technology
Topic: Another attempt at building a motor controller
Replies: 102
Views: 3075

Re: Another attempt at building a motor controller

did you looked on inductor ? does this SMPS runs in burst or continuous mode ? if you can change mode, try continuous..
by stepus
Feb 24 2021 2:09am
Forum: Motor Technology
Topic: Theoretical idea impossible? torque meter without torque meter for all motors
Replies: 5
Views: 251

Re: Theoretical idea impossible? torque meter without torque meter for all motors

yes it will work in complex system, but he asked if he can connect current sensing hall sensor output to controller throttle input - this will not work because he is not having user imput to control loop - manual throttle on bars. Yes launch control is easy system comparate to system of vehicle stab...
by stepus
Feb 23 2021 4:16am
Forum: Motor Technology
Topic: Theoretical idea impossible? torque meter without torque meter for all motors
Replies: 5
Views: 251

Re: Theoretical idea impossible? torque meter without torque meter for all motors

this will not work, if it can work, bosh yamaha and others will do that. imagine a starting it, how it will start ? when you power on there will be 0 current, so it will settle 0 throttle, when you pedal there will be same 0 current. If there will be some current at power on, it wil increase throttl...
by stepus
Feb 23 2021 3:59am
Forum: Motor Technology
Topic: Hub motor rewinding, what thickness of enamelled copper wire?
Replies: 25
Views: 924

Re: Hub motor rewinding, what thickness of enamelled copper wire?

Its better to use more paralel wires, its easy to hand winding, better use space in slots, and higher efficiency because skin effect at switching freq.
by stepus
Feb 19 2021 4:59am
Forum: Motor Technology
Topic: HESC V1 150v 600Amp VESC based motor controller
Replies: 24
Views: 1384

Re: HESC V1 150v 600Amp VESC based motor controller

Hi, i am very intrested in this controller, I want to build my own power stage, but if someone offers a allready made solution I do not oppose it :D I want to use it on surron, so 100V/600Amps is sufficient. About your power stage, why not use SMD transitor ? On my previously build controller for e-...
by stepus
Feb 16 2021 4:43am
Forum: Motor Technology
Topic: Water cooled car alternator
Replies: 28
Views: 1152

Re: Water cooled car alternator

Yes its a ferrite between teeths, i can measure thick of lamination when i will reopen alternator. Efficiency will never by comparable to profesional design motors, they have some simulations of fluxes softwares etc. but as DIY project with plenty of power and little heat it worth for that price :D ...
by stepus
Feb 14 2021 5:23am
Forum: Motor Technology
Topic: Sur-ron controller upgrade
Replies: 0
Views: 193

Sur-ron controller upgrade

Hi, I'm thinking about increasing power of my stock surron, for begining i would do BMS bypass battery and later maybe buy new 72V battery to double power :D Does anybody tried to "shunt" original X controller ? Or what you recommend ? Buy some aftermarket controller like nuculear/ASI ? Or...
by stepus
Feb 01 2021 10:48am
Forum: EBike Troubleshooting
Topic: limitation for a throttle ?
Replies: 4
Views: 254

Re: limitation for a throttle ?

I am a little bit sceptic about this schematic, it will lower voltage for hall sensor, and it can stop working under some voltage like 3V... Better i thing is connect trim pot as voltage divider from hall output, and centre of pot connect to original wire to controller
by stepus
Jan 31 2021 5:05am
Forum: Motor Technology
Topic: Water cooled car alternator
Replies: 28
Views: 1152

Re: Water cooled car alternator

yes, i ran it with RC ESC for that measurments i done, but i thought to mount hall sensors inside alternator, and use my own ESC with HALL feedback - there i can do same test as on my tricycle where i add a little PWM, motor lifts load to air, and then decreasing PWM to find spot, where motor is sti...
by stepus
Jan 30 2021 9:58am
Forum: Motor Technology
Topic: Water cooled car alternator
Replies: 28
Views: 1152

Water cooled car alternator

Hi, i have bought two water cooled car alternators, for remake a rotor with magnets. But i measured parameters like no load current, revs and BEMF. And its not bad at all. I wonder if it's not worth using as is and not remake it. Because I will have a variable "magnet strength" = variable ...
by stepus
Sep 03 2019 8:34am
Forum: EBike Non-hub Motor Drives
Topic: Car alternator conversion Back-emf
Replies: 0
Views: 499

Car alternator conversion Back-emf

Hi, i had converted two alternators, first the old one is 90A bosch, and there i have original rotor but i did it turned on latche to smaller diameter and glued neodym magnets from burned R/C motor - rotor have original iron teeths but with magnets. second is 120A alternator, i made my own rotor, fr...