flathill wrote:A solidslot motor! Watch out for eddy current losses in the conductors. In most motor designs the cross section of the winding wire is small enough to neglect eddy currents. Not sure if the tooth profile needs to be different for a solidslot motor, as to "shield" the conductors. Looking at a REMY motor with a hairpin winding makes me think you are likely OK, but just throwing it out there.
It will be an awesome and interesting learning experience to see how all the losses stack up. I have a feeling that the main dominant loss (I^2R) being reduced so drastically will make up for the other potentially increasing losses.
The stock motor has each half as 12 strands of 18awg, and the two halves paralelled for 24x18awg total. each 24x18AWG phase lead is 19.752 mm^2
If the new motor was wound with wire to match the stock amount, it would have 1/6th the turns, which would be 118.51 mm^2
both halves are in series, so it would only be 59.26 mm^2
With the solid-slot design, SW is saying the cross section will be 124 mm^2
, but that is assuming a .5mm nomex insulation wrap, and that the buss bar is a perfect fill in the slot. My machining is not perfect, so I will assume that the windings should be somewhere around 110 mm^2
, which is almost double the round wire copper fill