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Old Apr 19, 2011, 07:26 PM
Dale
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JATO for my Prius

I decided to bring my test stand home where I was working and the Prius was handy.
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Old Apr 19, 2011, 07:28 PM
Dale
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303 Posts
Test Stand

I set the stand up in the driveway when in use and I dragged it onto the porch when a test was over.
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Old Apr 19, 2011, 07:33 PM
Dale
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Joined Jul 2004
303 Posts
Winding Harness Jig

I decided to build a harness with all three phases of the windings pre-cut and joined at the WYE node. I will never need a DELTA termination so I decided that the node could be buried in the winding process. Each of the legs was 30 pieces of 23AWG 8 feet long. That means this jig was over 16 feet long.
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Old Apr 19, 2011, 07:36 PM
Dale
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Joined Jul 2004
303 Posts
Center of the Harness Jig

At the middle of the 16 foot long wires I had to remove the 1/4 inch long of varnish on each of the 30 wires with a diamond burr on my Dremel tool. Very tedious but effective.
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Old Apr 19, 2011, 07:38 PM
Dale
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Joined Jul 2004
303 Posts
Harness end terminations

I used 0.050" pitch circuit board to keep the wires organized.
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Old Apr 19, 2011, 07:40 PM
Dale
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Completed harness

The key to accomplishing this was to keep things organized.
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Last edited by KiloOne; Apr 20, 2011 at 06:52 AM.
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Old Apr 19, 2011, 07:44 PM
Dale
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Joined Jul 2004
303 Posts
Starting the winding process

Popsicle sticks were exactly the right tool to keep things in place and as some of you know there is no shortage of popsicle sticks in our house.

It was also very important to have a good winding map to follow as I went along.
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Old Apr 19, 2011, 07:49 PM
Dale
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Joined Jul 2004
303 Posts
Winding and winding ....

I was able to wind the stator teeth in numerical order, simply switching between the 3 coils as I went.

As it wound each tooth with 3 turns of a 30 wire bundle I simply rotated the stator and winding harness coils around on the desktop.
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Old Apr 19, 2011, 07:52 PM
Dale
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Joined Jul 2004
303 Posts
Socks and Tape

After I wound a few teeth I found that a pair of socks worked nicely to keep the coils that I was not winding, neat and tangle free.

Also, I taped over the stator teeth that were not being wound and other areas to prevent tangling.
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Last edited by KiloOne; Apr 20, 2011 at 07:16 AM.
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Old Apr 19, 2011, 07:53 PM
Dale
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The last step, rain or shine

Rain didn't stop me when I needed to spray varnish on the completed windings.

Where there is a will there is a way.
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Last edited by KiloOne; Apr 19, 2011 at 08:01 PM.
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Old Apr 19, 2011, 07:55 PM
Dale
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Success! 13 horsepower and running cool.

This was a good day!
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Last edited by KiloOne; Apr 20, 2011 at 05:54 AM.
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Old Apr 19, 2011, 07:58 PM
Dale
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Joined Jul 2004
303 Posts
4 kilowatts of Charging power!

Here is one of my charging stations, the second is still under construction.

It takes three circuits of 120 VAC to power this at 15 amps each! It weighs 62 lbs and will be mounted atop a 7000 watt generator that is on wheels.

A generator/charging cart will be wheeled to each wing of the Lazair where the three batteries in each wing will be connected.

The charging process will be started and logged by a netbook computer through wireless USB hubs mounted on the carts.
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Last edited by KiloOne; Apr 19, 2011 at 08:57 PM.
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Old Apr 19, 2011, 08:28 PM
I enjoy the voices
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Perth, Australia
Joined Apr 2007
484 Posts
Respect

Fantastic work - I'm watching your progress with great interest.

I have converted a car to electric - 23 kW worth of LiPos, and the car wound up with better acceleration than as petrol and only 70kg heavier than factory. So I have great respect for you converting a plane!
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Old Apr 19, 2011, 08:56 PM
Dale
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Great car project, how many kwhr of batteries do you have?
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Old Apr 20, 2011, 12:33 AM
JustFlying
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Joined Dec 2005
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Sorry to hear about your mishap Dale. At the same time, thanks for showing us the rewinding proses. Great experience you got from the proses.

Lead Wings, is it a BMW 3 series? Nice conversion. How long do you have it now? Cost of conversion?
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