Sensored motor availability??

[Whiplash]

Hello all, I was wondering if anyone has taken on the duty of selling motors with the hall sensors already installed? I am leaning towards your drive style VS the Hub I was going to use, but I am not sure I can get the components I would need to build the bikes in any kind of decent quantity. I really have to consider the ability to manufacture these as quickly as possible and if I have to modify motors and such for each build, it will be quite time consuming to say the least!

Thanks!

-Bryan

 

[spinningmagnets]

Some of the more affordable motors also have their magnets re-glued, and also have a higher quality set of bearings pressed in right from the start. The very expensive motors apparently don't need the magnet/bearing treatment, but both could use an "add hall-effects" kit that is user-friendly and has an easy-to-follow video.

 

[AussieJester]

Theres more than enough information on the forum that shows you how to fit the hall sensors, but no 'kits' of any kind as yet.

KiM

 

[Whiplash]

OK that's what I needed to know....I might have to wait a bit to go this route then at least for production. I just want to makwe sure I can supply these bikes if I am going to advertise them for sale...

 

[spinningmagnets]

Whatever you plan to sell, make one for yourself to show and to provide test-rides with. Make it exactly as you would the units you will sell. Reading some posts, and then putting it together yourself are two different things. Doing one yourself will give you a 100% understanding of all the details.

 

[Whiplash]

Yes, this is what I am planning on doing. I will and MUST build and test one before ANY sales think about happening... Don't worry whatever I build I will beat the hell out of it before I release it. There is no sense in selling something you will have to then fix when it breaks!

 

[liveforphysics]

It's not very easy to get sensors done correctly. It's actually a PITA.

Staticly located sensors are kinda limited to either being adjusted for either performance or economy, but not going to be optimized for either.

What we really need is the sensor adv/retard board that member Burtie is working on. Then getting sensors in the motor becomes loads easier, and you can get all the economy and performance you want.

 

[Whiplash]

Is it just a board that holds the sensors that you can just slide one way or the other? I have not seen it?

 

[Thud]

Are we talking outrunners?
I drew up a simple unit that will bolt to the bulkhead/mounting point for the 80mm can outrunner. It will be cast in urathane plastic & the halls & wires will be cast in place to mimic 120deg. spacing. looks like this:

I hadn't considerd on the fly timing advance.....would be relitivly easy to incorperate would just increas the size a bit. I think Bertie/Tiberius wer thinking an electrical advance gizmo that would be programable.(over this mechanics head)

 

[Whiplash]

OK so I am trying to figure out this in runner/outrunner thing, the outrunners the housing actually turns? If so, how would your design work? I guess I am lost here? I have exactly 0% R/C knowledge so help me out here??

 

[Thud]

Member Bertie can be credited for showing me the way to this set up

Here is a video I did to dispell the rumer that infineon controllers will only spin 5000 or 6000 rpms. you will see the can spins on these motors & there is a prototype hall sensor block mounted to the back of the motor.
shaky video-1 handing the camera & throtle while operating the tach with the other.
[youtube]wi5xW0tOYAA [/youtube]

there is another on 66ish volts running past 10k rpms. I have had a few issues with my controller odification set ups (i crossed the line on an order of magnitude) but am confident this is the best method of motor controll. Just need to sort some components & settings that will bring it all together.

 

[spinningmagnets]

Whiplash, yes the can/magnets spin on an outrunner. I had read a while back that this allows the motor to spin at much higher RPMs while still using inexpensive manufacturing methods and materials. A small imperfection in a common inrunner would lead to an out-of-balance condition once you exceed the max RPM-rating, with a sudden catastrophic self-destruction.

Also, Miles pointed out that because the magnets are thinner than the stator coils, this reversed arrangement also provides more torque per motor diameter, as the area of flux interaction is now farther away from the shaft.

 

[Whiplash]

OK, I thought that was the case, but was not sure. How is the spacing of the halls determined? I am guessing they are a type of magnetic sensor?

 

[Thud]

Here is every thing you need to know regarding the outrunners & added hall sensors.
http://endless-sphere.com/forums/viewtopic.php?f=30&t=15686

 

[Whiplash]

Thanks!

Edit: JUst finished reading this ^, MAN lots of good info there! I at least feel like I kind of understand it! I am thinking of ordering a motor and controller at least to start testing it out!