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Oct 25, 2018, 04:45 PM
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Quote:
Originally Posted by Takao Shimizu
Always problem of winding LRK.

Takao
Quote:
Originally Posted by Skylar
It's the copper inside the slots that contribute to torque.
Quote:
Originally Posted by bartk
Even with dLRK you don't have this.


You have to go to dLRK Evolution to get this

Takeo,
The crossover in the slot you show is just like what's shown in BartK first attachment. It can be avoided altogether by using a single per coil winding arrangement. The crossover wire at the outside of the slot are more subjected to proximity losses because of the higher flux seen in that area. Its may not be measurable in a kitchen lab but maybe temperature analysis can show this. For this reason id have the crossover wire deep in the slot versus the out side. I'm current winding a motor where I do the first single layer winding then add the second after that. For me its easier with no crossing wire in the way. Now I have 12 coils I can configure many different ways for all choices. I can reduce end turn loss by creating a end plate PCB that++ finalizes the terminations and phase connections.

Look at the attachment. This turnigy was wound per coil individually like servo motors for hill fill and joined outside the slot. You see no crossover wire in the slot. Its fine and runs the same way. In the best world a pcb end plate will ease terminations and possibly reduce resistance!

For a delta wind the pcb may help to give phase and inductance uniformity for a wye one 360 degree trace can handle all the phase end bundles then you only have to worry about teaming up the correct phase starts for each phase. Its all beautiful pie really. If you need a certain wind have no delay in asking me. I will gladly do this as you test very nice drives. Love the invaluable drive work you're doing .Any way I could help is welcomed. Feel free to ask. Ive also attached a photo showing the start of the newest single per coil winding arrangement with 1.7mm wire.
Last edited by 1boho; Oct 25, 2018 at 06:22 PM.
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Apr 21, 2019, 04:28 AM
homo ludens modellisticus
Ron van Sommeren's Avatar
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DIY Arduino based microohmmeter - RCG
Quote:
... has two auto ranges, 0-50 MilliOhms (0-50,000 uOhms), and 0 - 2 Ohms. ...
... Cost of materials is in the area of $25.00, Arduino included ...
Other diy projects by Denny Vollrath.

Prettig weekend Ron
Last edited by Ron van Sommeren; Jul 01, 2019 at 04:49 PM.
May 23, 2019, 06:20 PM
Ronaldo Nogueira
ronaldopn's Avatar

Grouping wire ends during rewind


In order to organize and prevent constant bumps during rewind (which could scratch the wire insulation) I use a heat shrink tube to group and contain the wires of already wound slots.
As soon as I finish one slot I insert it into the tube and continue winding.
Ronaldo
Jul 01, 2019, 07:09 AM
Jack
jackerbes's Avatar
It was a human winding error I'd say. That would cause a fluctuation in the power level delivered to the prop as voltage is applied to that arm and make for a little less power in that stator arm.

It might not have been apparent or even noticeable but all arms should have the same turn count on that nine arm stator. If it was a motor with a higher arm count an even number of arms and adjacent arms were wound and voltage applied to them as a pair, it would be OK to have a pair of arms that did not have matching turn counts as long as all of the pairs were wound the same way.

Jack
Jul 01, 2019, 02:16 PM
homo ludens modellisticus
Ron van Sommeren's Avatar
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Insulation characteristics
www.mwswire.com/insulation-characteristics

Vriendelijke groeten Ron
Last edited by Ron van Sommeren; Aug 02, 2019 at 06:33 AM.
Aug 23, 2019, 09:07 PM
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vimy g eaou's Avatar
Looking through these pages, your ideas, inspired me to handle the enamelled copper wire in a similar way to fishing line, to minimise the possibility of damage caused by scarring the enamel, twisting and kinks.

I recently purchased some cheap spool holders:

https://www.aliexpress.com/item/3284...3da24c4dEh5ksv

These components can be put on a common single axle and put into a frame.

And some fishing rod guides, to experiment with making simple winding tools:

https://www.aliexpress.com/item/3297...3da24c4dEh5ksv
Last edited by vimy g eaou; Aug 23, 2019 at 09:31 PM.
Sep 09, 2019, 09:17 AM
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Name: seite_20_hairpintechnik.jpg__1200x630_q85_crop_subsampling-2_upscale.jpg
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Size: 163.1 KB
Description:

Hi Takeo,
Hairpin motor windings are nothing new.Here is a paper from Ohio State's Yu Liu on how to create and lay them.
Youll enjoy the paper as a drive designer. SLOTLESS SIX PHASE DC MACHINE AND STEPPING VECTOR CONTROL. You can learn here how to get the true trap bemf and produce more torque production with your BLDC drives

TTYS
Last edited by H-1 (1boho); Sep 09, 2019 at 09:25 AM.
Nov 25, 2019, 05:07 AM
homo ludens modellisticus
Ron van Sommeren's Avatar
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Magnet wire supplier
www.awcwire.com (USA)


APCE Propeller Thrust Nomogram - RCG
Excel programs for estimating model in-flight performance- RCG
APCE Propeller Static Thrust & Power Nomograms - RCG


Prettig weekend Ron
Last edited by Ron van Sommeren; Mar 01, 2020 at 04:28 PM.
Feb 26, 2020, 11:38 AM
Ronaldo Nogueira
ronaldopn's Avatar

Quick wind with thin gauge wire for kV check


This may sound obvious but only now, after a few years of brushless motor winding, I had this simple but genius idea (I'm sure someone has done it before).
I never realized how useful it was until I did it for the first time.

So, if you are not sure about the original motor kV and can't test it anymore (i.e. burned or damaged windings) or if you are not sure about the results you may get with an unusual and experimental winding scheme, simply pick the smallest gauge you can find and do a test wind.
Using a very thin gauge wire will allow you to quickly wind and check the exact kV you'll get with it. Below is an example with my GA6000 rewound with half parallel dLRK Y wind for 164kV. The subsequent wind with 14AWG got exactly the same result.

Since currents during kV check will be very low, even a thin wire will suffice and provide accurate results.
Ronaldo

kV check on thin wire wind
Quick wind for kV check (0 min 6 sec)


kV check on the final wind (14AWG)
GA6000 164kV 11T hpdLRK Y 14AWG (0 min 6 sec)
Mar 01, 2020, 04:25 PM
homo ludens modellisticus
Ron van Sommeren's Avatar
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After almost a year of complaining and waiting, I still cannot edit the opening post to add info from or links to previous posts. Very annoying:
new type of 'sorry, you have been blocked' error message - RCG

Efficiency governs maximum power a motor can handle - RCG

Vriendelijke groeten Ron
Mar 01, 2020, 04:26 PM
homo ludens modellisticus
Ron van Sommeren's Avatar
Thread OP
(This-thread-only) moderator speaking ...

A little reminder.

Please don't ask general questions or help/assistance/information in this FAQ thread, just add your tips and tricks. I move/link information from posts to opening post, or link to the info, that way the information is presented in a logical (work)order.

This thread is not for problem solving or motor building questions, see opening post.

Please start a new dedicated thread when you have questions or when you are about to start a fresh motor/wind project. That way we keep this a lean and mean FAQ/tips/tricks/checks/tests/manuals thread. And your project/question will get more exposure.

I will let discussion run its course but every now and then I clean up this FAQ, information may disappear.

Bedankt Ron
Mar 22, 2020, 04:11 AM
Maiden>Confident>Cocky>Crash!
argo-2's Avatar
Quote:
Originally Posted by ronaldopn
I believe I have found the easiest technique to remove the wires from windings soaked with epoxy.
We all know that epoxy softens with heat but heating the entire stator (in an oven) is complicated and makes it difficult to handle later as the whole part gets hot.
My technique is simple, with a soldering iron equipped with a "knife" tip, spot heat the wires for about 30-40s close to where it is glued at the stator then pull the wires until they get stuck again.
Repeat the process until you can unwind the tooth completely. The epoxy is usually only at the 1st and sometimes 2nd turn and the rest unwinds easily.
This "spot heating" allows you to handle the stator with your hands without gloves for a much better control.
Ronaldo
Think I found an easier way Ronaldo
Mar 22, 2020, 03:59 PM
Ronaldo Nogueira
ronaldopn's Avatar
Quote:
Originally Posted by argo-2
Think I found an easier way Ronaldo
Cool, I'll try that, I haven't used my torch much, you just found another good use for it.
Ronaldo


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