May 04, 2012, 03:25 AM Registered User Joined May 2012 14 Posts Discussion Converting a 1/8 Ac Motor into a 48v bldc motor Hey all; I am towards re- winding my 1/8 (36 Tooth Stator)HP Ac motor into a 48v BLDC 3 Phase motor. I am confused about Winding my motor.Can anyone please help me how to build my motor as the rotor part is not a problem yet but the stator winding is the most confusing part for me. Please help me ;what sequence should i opt.
 May 04, 2012, 06:09 AM Jack USA, ME, Ellsworth Joined May 2008 19,852 Posts You can enter various slot and pole counts here and it will tell you the winding factor for the various combinations and show you a winding scheme too: http://www.powerditto.de/bewicklungsrechner.html As an example, if you enter 36N 30P it shows a winding factor of 0.93301, the closer that gets to 1.0 the better it is. I don't understand that motor, how many magnets are on the motor now? Jack
May 04, 2012, 06:17 AM
Inspiration
United States, MI, Ann Arbor
Joined Aug 2011
895 Posts
Quote:
 Originally Posted by ashkar_malik Hey all; I am towards re- winding my 1/8 (36 Tooth Stator)HP Ac motor into a 48v BLDC 3 Phase motor. I am confused about Winding my motor.Can anyone please help me how to build my motor as the rotor part is not a problem yet but the stator winding is the most confusing part for me. Please help me ;what sequence should i opt.
Is it an inrunner or outrunner?
To convert to a efficient brushless motor, you probably need to use strong magnets.
Is it an AC motor with magnets in, or there are just coils...
Are you sure it can be converted to a brushless DC motor?
May 04, 2012, 06:47 AM
Registered User
Joined May 2012
14 Posts
My motor is a Inrunner type motor;So please help me to wind the stator and how to calculate the poles that i might place in this rotor(Formulaes and eqations to calculate the parameters).

# Images

 May 04, 2012, 08:11 AM Jack USA, ME, Ellsworth Joined May 2008 19,852 Posts The link I posted it not going to help on the inrunners. Those things make my head hurt jjust to look at them... Jack
May 04, 2012, 08:35 AM
Registered User
The Northeast Kingdom, Vermont
Joined Jun 2004
5,866 Posts
Quote:
 Originally Posted by ashkar_malik My motor is a Inrunner type motor;So please help me to wind the stator and how to calculate the poles that i might place in this rotor(Formulaes and eqations to calculate the parameters).
Since that is an AC induction motor, what do you plan to do with the rotor? AFAIK, you'll need a new rotor with permanent magnets to run as as a BLDC motor.
Pete
May 04, 2012, 08:43 AM
Inspiration
United States, MI, Ann Arbor
Joined Aug 2011
895 Posts
Quote:
 Originally Posted by pilotpete2 Since that is an AC induction motor, what do you plan to do with the rotor? AFAIK, you'll need a new rotor with permanent magnets to run as as a BLDC motor. Pete
yea, that is what i guess, an AC induction motor. For both inrunner and outrunner AC induction motors, the rotor is not actually "magnets" at all. As Pete said, you will need to make a new rotor yourself, which can be a lot of work.
 May 04, 2012, 10:45 AM Registered User Joined May 2012 14 Posts I know that rotor is to be Lathed and fitted with approcriate magnetic poles of neodynamic magnets;but my problem is just stator winding
May 04, 2012, 05:01 PM
Inspiration
United States, MI, Ann Arbor
Joined Aug 2011
895 Posts
Quote:
 Originally Posted by ashkar_malik I know that rotor is to be Lathed and fitted with approcriate magnetic poles of neodynamic magnets;but my problem is just stator winding
Then you need to determine number of magnets first, before you wind the stator. I suggest that at least, you make a plan of how you gonna make the rotor first. Then you can go to the website Jack posted, you will see the winding scheme after you input number of both N and P. winding scheme may change if you input different numbers of P, and this is why you need to determine how many magnets you gonna put on the rotor first.

You will get a winding scheme for outrunners, but you can winded your inrunner stator in the same way, by following the same winding directions and connections..

In my point of view, constructing the rotor will be your biggest problem. You need to find a way to firmly fix the magnets, symmetrically. You will also need to balance the rotor. Consider the size of your motor, the rotor construction can be really the pin in the ass.
May 04, 2012, 05:07 PM
Inspiration
United States, MI, Ann Arbor
Joined Aug 2011
895 Posts
This is just an example of 36N34P, highest winding factor you can get from a 36N stator.

# Images

May 05, 2012, 05:48 AM
homo ludens modellisticus
Netherlands, GE, Nijmegen
Joined Feb 2001
13,826 Posts
Quote:
 Originally Posted by ashkar_malik I know that rotor is to be Lathed and fitted with approcriate magnetic poles of neodynamic magnets;but my problem is just stator winding
The cage must be iron to conduct and concentrate magnetism, not aluminium-alloy. The iron must be thin laminations, 0,35mm or thinner. In short, this is a dead end street, sorry

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Last edited by Ron van Sommeren; May 05, 2012 at 06:53 AM.
 May 05, 2012, 10:36 AM Registered User Joined May 2012 14 Posts @ Ron I already got a Stator but How to wind it ;No one have given me any help regarding that....Just pleaae tel me how do I wound the stator
May 05, 2012, 10:41 AM
I don't want to "Switch Now"
Joined Dec 2002
19,222 Posts
Quote:
 Originally Posted by Ron van Sommeren The cage must be iron to conduct and concentrate magnetism, not aluminium-alloy. The iron must be thin laminations, 0,35mm or thinner. In short, this is a dead end street, sorry
The rotor does not need to be made from laminations.
Steel tube of enough thickness to carry the flux with the magnets glued to the outside would do. Think outrunner turned inside out

Pat MacKenzie
 May 05, 2012, 11:15 AM Registered User Joined May 2012 14 Posts Any help related to winding stator
 May 05, 2012, 12:46 PM Wake up, feel pulse, be happy! United States, MN, Minneapolis Joined Aug 2009 13,494 Posts Help with winding the stator? Get some magnet wire of the appropriate gauge for the number of turns you want. It might take experimentation to see how much of what gauge will fit. Ideally you want the most copper fill you can get. Also make sure that the stator is properly insulated. You might want to use thin paper or plastic sheets on the stator arms for that purpose. From there, it's just a matter of winding the wire around the stator according to the winding scheme you choose.