Search found 41 matches

by mizlplix
Fri, 01 Aug 2014, 06:44
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

I have actually tested another motor in my car. It is an exact model of the same 20HP motor, except it is a 2 pole (originally) making the back iron slightly more and the stator has fewer but bigger slots, allowing more in-hand and a total wire length in between all of those we have done in the past...
by mizlplix
Thu, 25 Jul 2013, 04:16
Forum: Electric motors and controllers
Topic: Rewinding Toyota Prius MG2 stator
Replies: 12
Views: 3935

Rewinding Toyota Prius MG2 stator

When going from Star to Delta on an industrial dual voltage motor, the change was figured into the motor design and the current change was allowed for. The same can not be said for a single voltage motor when changed from star to delta. The current change will be double and place it in the danger zo...
by mizlplix
Wed, 24 Jul 2013, 18:53
Forum: Electric motors and controllers
Topic: Rewinding Toyota Prius MG2 stator
Replies: 12
Views: 3935

Rewinding Toyota Prius MG2 stator

Can anyone measure the stator slot width?
by mizlplix
Wed, 24 Jul 2013, 04:27
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

"To maintain that Vdc/Hz to 4000rpm (267Hz), we'd need to supply 1335V. Therefore, if we want to accomplish this with a battery pack of say 365V, we'd need to re-wind the stator for about 1/4 the voltage. This would be 1/4 the number of turns per coil and 4x the number of wires in hand, right?" Yes,...
by mizlplix
Tue, 23 Jul 2013, 06:35
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

Cool, I am far from knowledgeable on these. I DO know, there are several converters in California doing the plug in thing by removing the ICE and related stuff and adding another pack to the car. So, I would assume the electric motor will RPM just fine. The first group to do this is a bunch of engin...
by mizlplix
Tue, 23 Jul 2013, 05:35
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

One thought to ponder: The Prius only uses the electric drive up to a point (not sure), when the I.C.E. motor takes over. So even when you got it working OK alone, you will have at best a 30-35 MPH car. If you can over freq. the motor, you might pick up some RPMs there too. If rewound to 6 or 4 pole...
by mizlplix
Tue, 23 Jul 2013, 05:08
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

My new motor is installed and I am currently running it and doing controller optimizations to it. So far, it seems to be really good for my needs. I drive in town, so 50 MPH only is needed. I am getting a 56 MPH top speed. (direct drive car, no transmission) The acceleration is not "racecar" swift, ...
by mizlplix
Tue, 23 Jul 2013, 05:01
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

Plan: I just took time out and read your entire thread. It sounds like a really good project to simply rewind the stator to a lower voltage level and run a controller of your choice. Which controller do you want to run? What is the RMS voltage range of the controller? My motor is a 48 slot stator al...
by mizlplix
Thu, 18 Jul 2013, 08:38
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

Lol....that was the last try...it did pick up top RPMs, but there was no torque up there. That beast would run 6,100 RPMs no load. It would only do 3,500 RPMs or so under load. That was a bust. We then tried to change the phase spacing , but the controller went nuts. After the unit comes out of the...
by mizlplix
Thu, 18 Jul 2013, 03:43
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

I have returned from Tucson with the newest motor type. It is nicely wound, dipped and baked. http://i168.photobucket.com/albums/u200/mizlplix/043FCC00-1AF0-43B8-9FDD-9E1E6026555D-711-000001E47958395B_zps3d65e5ce.jpg It is 12 wires in-hand and two turns. 18 Ga. We decided to do the motor cables this...
by mizlplix
Thu, 18 Jul 2013, 03:31
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

"I have $7,000 invested in mine. I try to take reasonable care of them. They need to last me a while." I am referring to their ultimate life span. So far in this Lithium cell usage, there is not one instance where they have been used long enough to declare that they went >5,000 charge cycles or even...
by mizlplix
Wed, 17 Jul 2013, 18:19
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

True, the wiring and all connections will have an effect.

Those guys "testing" their cells do not care about damage either....
I have $7,000 invested in mine. I try to take reasonable care of them. They need to last me a while.

Miz
by mizlplix
Wed, 17 Jul 2013, 15:42
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

There is even a video of arcing a wrench across the top of one too, but I am talking about real world usage. I can do a 10-12 second, full throttle burst before I sag down to the 2.5 Volt mark and the BMS yells at me to cut back some. It is a function of needing another pack in parallel to really pu...
by mizlplix
Wed, 17 Jul 2013, 04:11
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

I am running a pack of 36/CALB 130AH cells. They will only put out 600 amps for a half second even if just off charger. They simply can not transfer lithium as fast as the motor can use electrons. But, it CAN provide 140 amps almost continuously. So, most motors with 18 ga wire and wound with 12 str...
by mizlplix
Tue, 16 Jul 2013, 14:54
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

Our first motor in my car was set up for 50-70 Volts. The second was for 30-60 volts. The third was for 70-90 volts. All were run on the Curtis controller. It likes #1 best. That is what I am going to run. I just need to change my final drive gear to suit. If I had another better controller, things ...
by mizlplix
Sun, 14 Jul 2013, 18:48
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

Yes. More voltage and frequency would mean RPM.
The new windings would be good for it too.
But I am stuck with a Curtis controller, and that is not possible.

They are maxed at about 70 volts RMS.
No matter what the DC input is........

Miz
by mizlplix
Sun, 14 Jul 2013, 12:05
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

Hi, Everyone: Sometimes progress is slow and other times progress is even slower... We finally got our motor rewound for the fifth time. Every time used a different variation of our first winding pattern. Every one ran but had some type of performance issue. The first one was the best all-around. It...
by mizlplix
Thu, 23 May 2013, 22:54
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

I spent the day taking my stator to Ivan's Garage in Tucson to get it rewound for try number four..... (as you remember,even though it performed well in traffic, #3 tended to run a little warm at 107C and pulled too much current-115 amps @ 40 MPH.) It is documented here: Ivans Garage Forums And a go...
by mizlplix
Mon, 13 May 2013, 05:46
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

This is the winding pattern for my 48 slot motor. http://forums.aeva.asn.au/uploads/2659/20hpwind.jpg It is for one phase and shows the four poles(groups of loops). If you cut it out of paper and bent it into a circle, it would be like the stator inside my motor. The start and finish is one pole apa...
by mizlplix
Mon, 13 May 2013, 05:38
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

Winding your own motor is not that hard, but it is mysterious until you have that last puzzle piece fall into place. Then you are amazed at how easy it was and why you didn't see it in the first place.... OK, A 3 phase motor has 3 separate phase loops of wire. (loop, circuit, coil, whatever) Each ph...
by mizlplix
Mon, 13 May 2013, 05:05
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

The Curtis controller throttles the motor through varying the frequency (VFD). It will do 300 Hz, which means about 9,000 RPM on a 4 pole motor. The RPM is limited by the stator iron saturation. That is partly mitigated by driving the motor up to the point of saturation, then weakening the magnetic ...
by mizlplix
Sun, 12 May 2013, 03:57
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

On 60Hz motors, we have a rule of thumb to use to determine the pole count. Number of poles                 RPM         2                         3,600         4                         1,800         6                         1,200         8                         900         10                    ...
by mizlplix
Fri, 10 May 2013, 09:40
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

That's why I always use a Ford 8.8 rear axle assy. I can get from a 2.73-6.14 ratio. And they are good for up to 500 HP.

(they probably hard to get in your neighborhood though)

Miz
by mizlplix
Fri, 10 May 2013, 03:57
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

You can not hurt the gearbox if you can not hook it all up. I am running skinny tires. I tried my best to kill a powerglide and a Borg Warner T-5 both. I know that the powerglide low gear does not like cruising at 6,500RPM +, it will cause premature wear in the planet gears. Yes, agreed. Better cont...
by mizlplix
Thu, 09 May 2013, 03:36
Forum: Electric motors and controllers
Topic: AC electric motor rewinding for EV use
Replies: 100
Views: 22468

AC electric motor rewinding for EV use

That was my very first motor. If I remember right, it was 24 in hand (those motor leads were 48 strands of 18 Ga. and one turn) The motor was based on a 7.5HP core. It ran OK above 1,500 RPM but the bottom end was kinda soft. This one was based on the 20HP core that we are now using. http://i168.pho...