1,500 watt edge 35mm D.D. repair

[99zip99]

I have an old 35 mm edge motor. ? This guy sold them for about a year and had to give it up. 8 years ago or so.
The little bamboo insulator sticks between the windings on the stator. It looks like they're moving and getting eaten up at various rates.
What I'm fixing is I cut the green Hall sensor wire and I had to take it apart and redo it all and shorten the wires and all the rest I got to check the Halls. Plus one of the bearings stuck on the axle what's the best way to keep it in the cover or does it matter much ? I had replaced the bearings with new bearing 8 years ago.

 

[tombenn444]

You could JB weld the bearing pocket ID on the cover and sand it to shape with a sanding disc and dremel

 

[99zip99]

I pulled the cover off the other side and found a broken copper winder in the windings can I solder it I guess they're insulated ?
I just put the halls in and decided to take the cover off to look at the other side. Meeting I haven't put the cover on and test it to see if it'll work with the broken wire. ?

 

[neptronix]

The only problem with repairing that broken winding is that you have to make sure it doesn't touch the others.
There's enamel/varnish on the wires for a reason!

 

[99zip99]

I read it earlier today but I can't find it now I think it was you Neptronix. The way I read it if there's one broken wire I would have to cut one out of each of the other two phases because these were so overbuilt ?

 

[99zip99]

That one strand of copper wire broken will make one of the three phase coils of the motor will make the motor unbalance ? I didn't see a way of spot weld or laser weld aa strand and insulate the one wire. It looks like that one wire was dropped on a rock ?
I still like the hope of the idea of cutting one brand of wire out of each of the three phases so they're all equal maybe ? Hope.

 

[neptronix]

I would solder the broken wire together, after filing a bit of the ends so that there's more non-enameled/coated surface to be soldered to.

You can do this without adding or subtracting any length, and find some sort of high temperature rated shrink wrap, or other insulating material, to put around the repair ( we don't want the solder touching the other windings )

 

[99zip99]

Okay I put some of that gold tape underneath it and soldered it I'm a big lump that's connected I tried to pull it apart with my fingernails. I'm going to now use 5 minute epoxy on that and the other wire that's a little shiny even though I gave it one coat already and then I'll cut the gold tape away. Then assemble. Thanks Nep I needed a push.

 

[99zip99]

Okay put some of that gold tape underneath scratch it clean dropped a piece of solder on it. And here's what I got.
I'm going to put some 5-minute epoxy on that the tape and everything once it dries I'll cut away the tape.
Okay I cut away the tape and there's a little bit of epoxy but molded on top and let it dry.

 

[99zip99]

So I got it all back together it seemed a little tight I ran it and it stopped I had tore into the Hall sensors that was the interference I was thinking about taking apart that white six plug all sensor plug and put a washer in between the cover and the axle but I didn't want to take apart the plug to pull the clamshell cover off.
Since I've been doing this 15 plus years I had a some leftover parts and I was looking about putting one of these washers in and I decided against it I guess I should have but then I wanted the clamshell cover to properly seat and not float in the air on those seven 4 mm cover nuts. Plus the bearing stuff on the shaft when I took it apart I knew there was problems maybe the outer part of the bearing was turning inside the clamshell making it fit closer in to the stator ?
Well I can run it sensorless as it's a 35 mm motor.
But I got other motors and projects that deal with.
And with my two bad knees I don't want to be breaking down this thing's just going to have to be shelved maybe a wind turbine
.h