Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

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etard   1 MW

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by etard » Nov 14 2011 9:54pm

Hey T,
I'm having a hard time trying to find out the torque output of your custom wound motors, do you know the newton meter output at say 5kw? Is it 17kw as Miles stated earlier? The reason I ask I that I am debating on tryin to slim down the drive further by mounting one of these inside a jackshaft pulley after a 2:1 reduction so I'll need twice the output rating as the motor:

http://www.vxb.com/page/bearings/PROD/O ... s/Kit10970
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Thanks to Justin @ http://www.ebike.ca He brings the soul to ES

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by Thud » Nov 14 2011 11:25pm

Here's a SWAG at it.
looks like nearly 15 Oz/in per amp as Kt...soooooo, at 100 amps your makin' 1500 oz inches or effectivly 8Nm of torque at the motor shaft.

multiply that by whatever your reduction is & you'll need a bearing rated at 10x that for reliability.

(scientific wild ass guess)
get some......

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by kfong » Nov 14 2011 11:52pm

Bearing, I went through my notes is this what your looking for?
Attachments
For-Thud.zip
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running_flux_0.jpg
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Last edited by kfong on Nov 15 2011 8:21am, edited 1 time in total.

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by Bazaki » Nov 15 2011 3:25am

After rewind, would it be possible to add watercooling ? And has someone done this before or any idea how this can be made ?

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by Thud » Nov 15 2011 6:14am

B,
there is a long discussion about cooling these motors starting on page 7 (it continues for 7 pages) lots of ideas & a test....but we definitely need more testing & ideas, if limits are to be explored further.
get some......

All information & advice provided by Thud are "Open Source" & free for personal use & distribution under the following agreement linked below.
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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by Ludo91 » Nov 15 2011 6:19pm

guys... As I told ya in my topic "help in building my own bldc controller" I put the "hot stuff" about my ebike on the shelf in order to be able to work hard for college... but still I cannot resist to do some little works on the bike, one of these days Im gonna try to put a ductjed fan on the top of the motor to see is forced air cooling does something cool... i`ll keep u up to date... it may be a while tho :wink:
Open source high power BLDC controller! ===> http://code.google.com/p/dc-brushless-o ... ontroller/

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by bearing » Nov 15 2011 6:40pm

kfong wrote:Bearing, I went through my notes is this what your looking for?
Yes! those are the files.
Many thanks man=)

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etard   1 MW

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by etard » Nov 15 2011 9:20pm

I am in the middle of training hamsters to fan the motor with feathers, but now that you mention it, a ducted fan sounds almost as easy. :lol:

But why even have an external motor when a fan can just be mounted on the shaft? Hey Thud, weren't you working on something similar? Of course you know my thoughts on the subject which imay have to incorporate on the Racer X build.

By the way guys, I just got two of Thud's latest winds and the pro winder is starting to become a Jedi, so save yourself some headaches and have him message you motor.
Four wheels moves the body, Two wheels moves the soul
Thanks to Justin @ http://www.ebike.ca He brings the soul to ES

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by RWP » Nov 15 2011 9:41pm

etard wrote:...By the way guys, I just got two of Thud's latest winds and the pro winder is starting to become a Jedi, so save yourself some headaches and have him message you motor.
OK then, tell us - show us what you got :mrgreen: What winds and such - and pics to match :D

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by etard » Nov 15 2011 10:11pm

Ok then Roy, you asked for it!!

Image
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Then one just to make you jealous, there's over 15 kw of potential there:

Image

I'm thinking of sending this 80-85 in for a wind, I actually want to bump up the KV a bit closer to 200 with better bearings to take the abuse along with hall sensors for the ultimate option.


One thing I must say, be sure to get the Thud 4 1/2" shaft cut off signature! I do believe the guy carries extra cutoff disks in his wallet where condoms used to reside. :lol: :lol: :mrgreen:
Four wheels moves the body, Two wheels moves the soul
Thanks to Justin @ http://www.ebike.ca He brings the soul to ES

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by RWP » Nov 16 2011 2:09am

Looking just beautiful 8) You're going to kick some butt with those baby's :mrgreen:

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bandaro   10 kW

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by bandaro » Dec 05 2011 8:22pm

So is there a diagram in simple english about the finishing stage? I'm a little confused as to how to finish the wye winds, Delta is split into 2 from the start right?

Sorry if it has been answered already, just trying to wrap my head around this as a holiday project, would love to rewind a 63-74.

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AussieJester   100 GW

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by AussieJester » Dec 07 2011 9:27pm

hehe Oi, "Soul Patch Boi": :-P :-P ..i see your 80-100s and raise you a CA-120 ... :-P YuP i got my
hands on a brand spakin' new CA-120...ThudSTeR has hooked me up
with a shaft magnet wire and that nomax paper to stop shorting

Aside from ThuDSTeR has anyone else here rewound one? I pulled my (never been used)
CA-120 apart last night
FILE0005.jpg
FILE0005.jpg (100.57 KiB) Viewed 3410 times
Just waiting on a confirmation from da MaN ThuD on the number of turns i need on this beast,
Be interested to here from anyone on EnDLess SPhere thats tackled a re-wind on the CA-120
and how it went?

Shall start a new thread for the re-wind when i get into it i think, i want to
run this on 66v LiPO config using a 12fet heavily modded Infineon
mounted in another custom 4130 ChroMo 'BasMaN' rippoff frame
hehehe...Wish Me LucK boiz :-)

KiM

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by E-racer » Dec 30 2011 4:15pm

I finally went ahead and stripped my 80-100 for a rewind. The goal was to be able to use a single stage reduction into a nuvinci dev kit. I choose 12t delta for 88kv. This allows me to use a 10:1 reduction into the Nuvinci for a speed range of 16mph-58mph (overdrive). Its not as perfect as Thud's rewinds but this was my first one. A couple more tries and I think I could do much better.
Image
Image
Kona Stinky: custom swing arm w/ batteries
-13s3p Turnigy Li-po
-Turnigy 80-100 rewound 130kv (Burtie's optical board)
-Kelly KBL 48201
-Nuvinci Dev Kit
http://endless-sphere.com/forums/viewto ... 28&t=35341

Goped ESR750
-12s2p Turnigy Li-po
-Turnigy 80-100 HXT w/halls
-Kelly KBL 48201
http://endless-sphere.com/forums/viewto ... 35&t=20732

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by bearing » Dec 30 2011 5:05pm

Nice work. Did you use any tools?

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by mauimart » Dec 30 2011 6:34pm

E-racer wrote:I finally went ahead and stripped my 80-100 for a rewind. The goal was to be able to use a single stage reduction into a nuvinci dev kit. I choose 12t delta for 88kv. This allows me to use a 10:1 reduction into the Nuvinci for a speed range of 16mph-58mph (overdrive). Its not as perfect as Thud's rewinds but this was my first one. A couple more tries and I think I could do much better.
Looks great. What size wire are you using? Looks like about 14 AWG. Have you measured the phase resistance yet? I did a 9T wye using 14 AWG and it's performing well - low kV and have not destroyed my controller yet.

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by E-racer » Dec 30 2011 7:04pm

Thanks! Yes im using 14 gauge. Resistance values were equal between phases I cant remember the values off the top of my head. Believe it or not I modified a couple tooth brushes for poke/pry tools. I haven't run the motor yet (waiting on Burties optical hall setup) but I hooked it to oscope and all looks good. I still have to do a final test then epoxy a couple places to reduce the risk of the coating chaffing.
Kona Stinky: custom swing arm w/ batteries
-13s3p Turnigy Li-po
-Turnigy 80-100 rewound 130kv (Burtie's optical board)
-Kelly KBL 48201
-Nuvinci Dev Kit
http://endless-sphere.com/forums/viewto ... 28&t=35341

Goped ESR750
-12s2p Turnigy Li-po
-Turnigy 80-100 HXT w/halls
-Kelly KBL 48201
http://endless-sphere.com/forums/viewto ... 35&t=20732

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by bandaro » Jan 22 2012 4:58am

Ok guys, I'm just wondering on wiring options here at the moment, so any comments are appreciated.

I have an old 6374-170 motor, taken the windings out, and looking to rewind it for around 65kv if possible. What I want to know is what will be the best way to do this to get the most power from the motor, should I go more turns and finish it in delta or less turns a finish in wye? I will get a controller later, so am really just looking for the best configuration that will leave me with safe options for a controller, either rc or otherwise, while still having as much power as possible. Hoping to put it in a dh bike through the bb. I currently have a dj bike with a bb drive, but wanting to make a dual suspension build sometime soon-ish.

Thanks in advance for any help, I'm not too motor savvy...

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by Kin » Jan 22 2012 1:35pm

I'm with Bandaro, but not going to work on that project for a while. This thread has always interested me so I just want to subscribe right now. I've seen a lot of rewinds with the 80-100 so I figure I could just follow someone's formula if I wanted to do that (meaning, someone says you can get, e.g, "XX turns with YY gauge wire"), but I haven't picked up on anyone doing this with the 6374 series. I'm sure someone has, just I haven't seen their thread or posts yet.
New to endless-sphere? Notice a lot of signatures recommending Ebikes.ca? That's because it's the best place for a quality and manageable, (but still 'real'), first build. Justin is a solid supporter of electric bike development, and a good source of equipment.

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by thepronghorn » Jan 24 2012 12:23am

This is the only 6374 motor rewind I've seen posted. It's about the Towerpro 5330 which has a similar stator diameter to the 6374 motor.

http://endless-sphere.com/forums/viewto ... 28&t=14410

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More 80mm tweaks for fun...

Post by Thud » Jun 03 2012 10:23pm

Had a productive afternoon polishing the 80mm outrunners.
I wound a motor today to power my FS 29er build...since I will be pounding this motor, I thought I would try to air cool it with a few of my personal stylings. cooling: The motor is wound as LRK & terminated in wye...this leaves 6x more area for cooling air to flow thrugh the motor...& odd as it seems I still have a 25% increase in copper over the stock wind's

Image

Now that the motor will pass some meaningful air through it, we need a little air motivator...so I patterned one up & made a mold so I can make these in #s I have a few motors laying around that will benifit from forced air cooling:

the rough plug:
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super glued to a piece of aluminum so I can chuck it in the lathe:
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A few minutes later it looks like this: (I love mahogany)
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So it can do this:
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A little Lacquer & some vents & its ready to cast the mold:
Image
Image

Now for the gooey silicone liquid tooling
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all poured & ready to cure:
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after 18 hours I can make the bottom 1/2 of the mold....then in a short 18 hours I can cast blower fans till the cows come home.
yes they will be available for your motors too.

hope you had fun following along.
I'll post the actual kv from the re-wind after a spin up...

all or your 85's are belong to us......
Image
Last edited by Thud on Aug 03 2012 1:13pm, edited 1 time in total.
get some......

All information & advice provided by Thud are "Open Source" & free for personal use & distribution under the following agreement linked below.
http://creativecommons.org/licenses/by-nc-nd/3.0/

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by Kin » Jun 03 2012 10:37pm

Your casting is very cool! Just casting, period, is pretty cool.
New to endless-sphere? Notice a lot of signatures recommending Ebikes.ca? That's because it's the best place for a quality and manageable, (but still 'real'), first build. Justin is a solid supporter of electric bike development, and a good source of equipment.

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by deVries » Jun 08 2012 8:24am

More 80mm tweeks for fun..

Unread postby Thud » Sun Jun 03, 2012 10:23 pm
Had a productive afternoon polishing the 80mm outrunners.
I wound a motor today to power my FS 29er build...since i will be pounding this motor, I thought I would try to air cool it with a few of my personal stylings. cooling:
The motor is wound as LRK & terminated in wye....this leaves 6x more area for cooling air to flow thrugh the motor...& odd as it seems I still have a 25% increase in copper over the stock wind's
Todd,

You've become a real artist at winding & modding these motors. Amazing work & one of the very best threads on ES. :D

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by Jeremy Harris » Jun 08 2012 11:42am

I'm seriously interested in seeing how this works out Todd, both the fans and the LRK wind. I have two 80-100's here mounted on a common 12mm shaft that I want to run as a single motor, with the drive being taken from the centre down to a jack shaft and then to the rear wheel. It so happens that a pair of 80-100's "just" fit into the space where the air filter used to be on my RD50 project bike, which would leave almost the whole of the former engine/gearbox area free for batteries.

What sort of Kv are you aiming for with this motor?
Please ask questions on the forum, rather than by PM, as it helps others and you'll get a better range of answers.

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Re: Re-wind of a turnigy 80/100 (Now-tutorial w/Video)

Post by salty9 » Jun 10 2012 7:33am

#42 water cooling an agni http://www.diyelectriccar.com/forums/sh ... 753p5.html

Distilled water only?

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