First hub motor rewind

[Skedgy Sky]

Update: Go down to 4th post, as I've decided to rewind it.

This motor failed while it was cold probably when two connectors came in contact with one another (this was months ago).

Today I decided to attempt to rewind it and so I was cutting away at the windings (did some labeling, mainly one phase as the other two were shorted and would have proved to be difficult); this is my first motor rewind, by the way.

After cutting up part of the first yellow phase, I decided to see if I could locate the short between the blue and green phase.

I kept my multimeter testing for continuity between the blue and green phases (as they are shorted together. Note:the wye is seperated
I got down to the last strand of wires.... and just out of curiousity decided to cut the charred wire from the strand which resulted in loss of continuity between the green and blue phase (somewhere along this wire must have been where it was short-circuiting the green and blue phase!).

Granted, this was the last set of wires I got down too but the charred wire must have meant something...

Now I'm not sure which route I should go with:
Do I continue on removing the windings and rewind the whole motor or do I reconnect all the connections I broke and hope this charred wire was the cause of the death of the motor?
I've circled in red the area in question.
http://i.imgur.com/mYo1oSS.jpg

 

[roller]

I would vote not to "hope" you "fixed" the problem, but to make more measurements and understand better what is happening.

It looks like you are cutting the interconnects (crossovers between poles of a given phase), and if the charred wire is a strand of an interconnect, then it certainly should not short to 2 different phases.

I would recommend to clean off a little varnish from each side of the cut (charred wire) and find the other end (continuity / ohms) of each side of the cut. This is harder with other interconnects already cut, but that just means there are more places to check. You should be able to find the other ends of each side of the cut wire.

Now what do you find? Do they both go to the same phase? Or does one side ring through to 2 phases (still has a short) ?

There is a little more information you can gather (maybe find/remove short) before undoing the whole winding -- while it is still (though tedious) salvageable.

-=r=-

 

[Skedgy Sky]

This motor issue is actually from a previous thread, however since then I had decided to rewind it today after not being able to solve it. ( http://endless-sphere.com/forums/viewtopic.php?f=2&t=51104 )

But before your reply I had already decided on at least connecting all of these "interconnects" back together and trying the motor (after snipping the charred wire of the strand of wires) since there were reportedly no shorts among the 3 phases anymore (when they were separated at the wye, even after connecting the interconnects back together).
So I put the motor back together, with the inside now looking like this:

That's masking tape, by the way.

I tried it out and the motor only seemed to work properly backwards but forwards pulled more amps than normal (and ran really loud) (halls were not changed and phases were connected properly; I tried many/all configurations, even the ones I knew worked before the issue came up).
Even if I was able to make it run forwards properly, the mess that now sits within the motor (the interconnects being bridged together again) may down the road cause me more issues... so I think the best choice for me now is to rewind the motor.
I will get on with removing the current windings (and most likely also seeing how they are wound in the process, as I'm fairly new to this winding business) Thoughts?

 

[Skedgy Sky]

Changed the thread title... Okay... so I have most of the windings out at this point.

Is it necessary to put in new insulating paper or can I reuse the old one?

I've read some posts on the following already, but still am not sure what wire to go with...
I'm aiming for being able to put a lot of watts into this (compared to what it's rated for originally), would this mean I should either go with thicker wire and/or more parallel strands on the new wind? Is 16 guage wire a good size to go with?

 

[bigmoose]

You can reuse the old paper as long as it is intact. Especially important on the edge where the wire will make the turn over the stator. That sharp edge needs 100% protection for the wire.

 

[Skedgy Sky]

I got the first winding sequence while removing the winds, however it may be wrong.
The second one was provided by: http://www.bavaria-direct.co.za/models/files/Winding_Scheme_Calculator.htm

????BbBCcCA??AbbBc??CAaABbBCcCcAAABBBBCcCAAA?bbb???
AaABbBbcCcaAabBbBCcCAaAabBbcCcaAaABbBCcCcaAabBbcCcC

Not entirely sure whether the site is correct or how much of mine is correct... help would be appreciated.

 

[Thud]

Is that a clyte H_35xx series motor?
The calculator you linked to is good medicine.
Also have a look here:
http://endless-sphere.com/forums/viewtopic.php?f=30&t=43781&start=25#p643798
Have fun...

 

[Skedgy Sky]

Is that a clyte H_35xx series motor?
The calculator you linked to is good medicine.
Also have a look here:
http://endless-sphere.com/forums/viewtopic.php?f=30&t=43781&start=25#p643798
Have fun...

I think it's a Conhis motor; not sure... just know it's one that comes with those generic amazon / ebay kits.
I now realize that the linked winding scheme (with same tooth/pole count) appears to be the same as mine, despite the different motors... thanks! I'll order some wire and see what I can make of it.