Revolt RV120 rotor remake

Electric Motors and Controllers
larsb
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Re: Revolt RV120 rotor remake

Post by larsb » Sat Aug 26, 2017 1:16 pm

I think the plug will be OK, need to sand a liittle bit on some spots. Thanks a lot for the effort!
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Magnets have left china now and are on the plane. I will have to check the true measurements of the magnets when they arrive, i've seen some suppliers do really poor dimensional control.

I realized i made an error on the prints, the magnet pusher and spacer rings were made for 3mm magnets so i need two new spacer rings for 5mm magnets and a new pusher. Do you feel like printing some additional parts?

I can make some stls next week if you do.

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Wheazel
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Re: Revolt RV120 rotor remake

Post by Wheazel » Sat Aug 26, 2017 1:48 pm

Yeah, no problem!

larsb
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Re: Revolt RV120 rotor remake

Post by larsb » Wed Sep 06, 2017 11:40 am


Karolis
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Re: Revolt RV120 rotor remake

Post by Karolis » Fri Sep 29, 2017 1:52 pm

Is there any news about new rotor?
Currently made rear swing arm with RV160PRO and looking for a reason to continue my project or just dump it. I'm in crossway.
https://www.youtube.com/watch?v=TWaFExhQsjg

larsb
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Re: Revolt RV120 rotor remake

Post by larsb » Sat Sep 30, 2017 1:01 pm

I just got magnets!

But it will be quite a while before there's any real progress.

I am convinced that it won't be a huge improvement though! These motors just aren't top performers. If you can wait until christmas time then i will have some results.

Whats your main issue with the rv160?

Karolis
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Re: Revolt RV120 rotor remake

Post by Karolis » Mon Oct 02, 2017 3:31 am

The main problem for me is the rotor. It is completely inaccurate. I tried to balance it. So it is on the limit for me. Also there is a huge magnetic flux leakage.

larsb
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Re: Revolt RV120 rotor remake

Post by larsb » Mon Oct 02, 2017 5:38 am

Ah, have you contacted Revolt? they should give you a new motor on warranty. I remember your picture, that's not possible to explain in other terms than it is a defect motor
Then you can try to fix the bad one if you feel like it :D

larsb
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Re: Revolt RV120 rotor remake

Post by larsb » Thu Oct 19, 2017 12:55 pm

I have been busy with making a gearbox, rotor remake is on hold for a while. I maxed the revolt yesterday and the rotor got so hot that i couldn't touch it. I think my odds to get a large improvement on the rotor are quite good!

larsb
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Re: Revolt RV120 rotor remake

Post by larsb » Mon Nov 20, 2017 3:43 pm

I had too much time to think about it.. Once i start to make a new rotor i might as well extend the stator. I have enough magnets..
So i contacted Revolt to see if i could buy some extra laminations. Apparently they are improving their motors so they now have 0.3mm stator laminations available for the RV120!

I bought a 60 mm stack of laminations, i will get in in roughly a week.
It will be a 33% longer stack than original and i hope to fit it in roughly the same space. Should be possible with some creative milling of the end covers.

If i could find some lathe assistance then i might just do a watercooled stator hub.
Anyone up for it? :D
Should be relatively easy job, just an alu cylinder with 50mm diameter, around 100mm long, two end stubs for holding and two grooves for snap rings to secure the sideways movement. I'll glue the stator stack once it's in place so the snap rings are then mostly to keep the bearings from going too far in.

I'll mill the cooling channels and make new end covers if i do it. Could be fun!

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macribs
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Re: Revolt RV120 rotor remake

Post by macribs » Mon Nov 20, 2017 4:14 pm

Wow you just took this remake from absolute hard core, way into the next galaxy.
Less eddy current so even less heat at high RPM and liquid cooling to top, I like it a lot. Now make sure that thing gets a controller worthy of your Remake. The controller you choose must have a lot of peak amps to give you the acceleration you so deserves after putting in those man hours and lang nights.

Man I look forward to see how this turns out. Keep on making good choices for your motor and your stamina will stay high and safeguard you to the finish line.

John in CR
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Re: Revolt RV120 rotor remake

Post by John in CR » Mon Nov 20, 2017 9:14 pm

Now that I have the last 12 in existence, I should send you 2 of my MiniMonsters 150mm X 50mm stators for a rewind to a Kv of 30-35, one for you and one for me. Sure they're heavier than a 120, but you'd be guaranteed a 20-25kw (even at just 74V) high efficiency motor. Wound to a higher Kv and dumping the 2 speed wiring would increase efficiency beyond the 93% the original tested at, as long as you meet or exceed the factory copper fill. I have faith in you. The lams are .5mm, but are top quality Japanese laminating steel, not ? quality stuff from people who already let you down.

Karolis
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Re: Revolt RV120 rotor remake

Post by Karolis » Tue Nov 21, 2017 3:44 pm

I don't think it is a good idea. To start from beginning again. You already have rewinded your motor. You only need to check first even if it is worth doing by making new rotor. If you will find that there is some improvements, then you should step it up. I would do that way if I was in your position.

larsb
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Re: Revolt RV120 rotor remake

Post by larsb » Wed Nov 22, 2017 6:04 am

It is not worth doing, i agree!

I have been riding the new motor for several months now and it works great for me. But i have decided to try a new rotor and from there the next step is easy except for the water cooling.

I plan to rewind the motor i don't use and give it a star connection.

The reason for this is to be able to use the retro direct gearbox i am designing

Delta winding is difficult to switch directions on as it needs a 30 deg phase shift from CW to CCW rotation.
I might just use the existing stator hub and skip the water cooling to keep it simple. Haven't decided yet..
Last edited by larsb on Thu Nov 23, 2017 4:14 am, edited 1 time in total.

Harold in CR
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Re: Revolt RV120 rotor remake

Post by Harold in CR » Wed Nov 22, 2017 8:00 am

I have been riding the new motor for several months now
Are you referring to the rewound motor with square wire or a completely new factory wound motor ? Really nice thread on the rewinding. Thanks for the details.
Thanks to Justin, the forum is open source and NON-commercialized.

larsb
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Re: Revolt RV120 rotor remake

Post by larsb » Thu Nov 23, 2017 1:10 am

I am referring to the square wire rewound motor as "the new motor" :D

I paid 35usd for the laminations which i think is ok if they are at least as good as the 0.5mm lams steel.

@john in cr: what's the dimensions of the motor (not only stator)? winding (to me) is the worst part and i don't think i have what it takes to do several motors..

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