some news:
bofore i'm sharing more pics and info about that motor conversion, i want to report how the test run with Adaptto controller was.
in short: DISAPPOINTING, but now from the beginning on..
I swapped the phase and hall wires as long as the controller did show a "hall offset of 0 degree". I did so because it was mentioned that it could have an effect on performance if the offset is 60°, or 300° or something like that..
Ok, than i did manual tuning and everything seemed to be fine, like the no-load speed were exactly how it should be concidered the battery voltage, motor kV and about minus 7% because of sine wave.
the no-load speed was 75kmh at 84 volt, and the display showed a consunption of 120-160watt which should be ok.
Already during the setup i noticed the terrible noise the motor makes. When i did the tests with the bare motor, the sound was quite normal, but now as it is laced up, it is a differnt thing.
It seems like the wheel with all it's parts (rim, motor housing) amplifies the switching frequency like a loudspeaker so much that it becomes definitely annoying. It doesn't matter if WITH or WITHOUT throttle (when the motor is spinning down), the sound is always the same and very loud.
With the bike on the road, the noise wasn't that annoying anymore, but something definitely must be wrong as the performance is very poor.
I have set 60/100A in boost mode, so above 5kW, but it felt like maybe a 500-1000W powered bike, and the temperature limit of 100°C was reached very fast.
It looks like Adaptto doesn't work with that motor, and i personally don't know on what settings i could turn further to make it work properly.
It is a pity!
Whats planned now:
As soon as i received the 100V 12Fet controller from PV, i will hook it up on that bike together with a CA.
Adaptto is known to have issues with a few motors (like Crystalyte TC series), so there might be a good chance that it will work.
here are the rest of the pics i took during the conversion:
the axle is a piece of art. it has 3 wire channels and nowhere sharp edges. Bravo Bionx!
the wire channels also have the function for torque transmission.
i was able to fit 3 x 1,5mm² wires into one single channel, so the total cross section is 3mm² per phase.
the third channel was for the sensor cable
the location of the two thermistors (one is NTC 10k and the other KTY type)
lacing straight pull spokes is really easy compared to normal J-bend spokes
that special torque arm design doesn't shift the axle center (like usually high power hubs do with M14 or M16 flat part), so no problems with the installation of the disc brake caliper
and finally the D-motor on the bike
Guys, i don't think that large diameter motor looks that ugly or strange
whats your thoughts?