Andje said:
so i toasted my HS30
It happened while at a conservative speed on the way home, not while accelerating or while at my highest voltage. Still working on getting one of the side covers off, so i can only see the side of the windings with the halls, but there was clearly some sort of phase wire short. It either melted near the solder connecting the windings to the phase wires or it just strait up melted some of the phase wires in place. The rest of the windings are a healthy dark used color, but the only black is arround the shorts and the area it all screwed up. I will definitely be rewinding this motor and i guess biting the bullet with the cooling holes. Until then it is back to a conservative 75km/h top speed on my 9c... unless i melt the phase in that one too.
Sigh... 40 hours of hand labor, here I come. O well, i will end up with something more reliable after I'm done...
Re-winding is not much fun.
I bought 40lbs of 14awg.
Determined it's too stiff to work with, though it is possible to get 7-turns on each tooth, and a pair of wires making 4-turns is POSSIBLE, but I was never able to do it without crushing/shorting the insulation. Expect to ruin your fingers before you finish 3 of the 51 teeth.
So, I bought 40lbs of 16awg. It turns out to be just slightly too thick to make a double row of turns (for each tooth, so 4 layers in the slot). It's also pretty hard on the hands to work with, though not nearly as tough as 14awg.
Next I bought 80lbs of 18awg. This wire works pretty well for winding. You're going to need 3-4 strands in parallel. The best copper fill we could manage with 18awg is only a couple percent above it's factory wind though.
So, I bought 25awg and 27awg. Both of these wind really damn nice! Easy to get good copper fill percentage, never had any shorting issues, it's easy on the fingers. What isn't easy is making the winding jigs and crap to put 30-40 strands of it in parallel long strings. In fact, after spending ~8hrs trying to create the bundles that we needed, and ending up with 10lbs of copper rats-nest, we scrapped 25awg and 27awg and went back to 18awg, which gets us worse copper fill, but does make the wind possible to do without specialized machines. If I had managed to buy something like 40 x 1/2lbs spools of 25awg, we would happily be using it, because I think we could keep it from being a giant rats nest.
So, back to 18awg is where we are at... It makes re-winding the motor only slightly beneficial for us... but whatever.
Paper in the slots. Get motor/transformer paper. Put it in your slots.
Things that failed (insulation shorted to stator).
Paint.
Kapton tape.
Electrical tape.
Normal Paper.
Plastic film.
All of these things failed during winding.
Transformer/motor paper worked. It's like an extremely fibrous cloth-like paper made for not letting wires chafe through it into the stator edges. Costs about $10 for a giant sheet, 100% worth every penny.
Also, I've got over $600 and >20hrs into RnD on re-winding, and my motor is still only about half done.
That was the entire point of the buy - to get people testing the limits ASAP.
