Alternative motor windings and drive schemes

[Clugh]

Ralph never showed his friends in Germany other winders work in America and other countries....

[Clugh]

Modisc HKIII 4035
6+6 1.5 mm

[Clugh]

Another HKIII4035, 12N10P,
1.3mm, 7+9T, YY
Kv350
💣

[Clugh]

The Asiatic brother can wind. Powercroco can't hate. The work is impeccable and definitely up to par with anything that has come from there.
Ralph stole the idea of Kapton slot liners from us. We both used it alot earlier in our winding programs.

Now that's all the croc winds on as the Motorfuher.

[Clugh]

HK4025 12N8P

STSD winding

1.3mm, 7+8 Turn delta
1.5mm, 5+6 Turn delt

Hi Ralph...
Thanks to you we will hit 30K today and a few new members will sign up for the thumbnails.....

We all know you're the best...even though you share none of this winding work you know all about with your friends in Germany....

TTYL
Hubert

[Clugh]

Here are 7 turns of 13 AWG 1.828mm on the 40 mm stator from mo. This would be a great Scale boat outrunner.

[Clugh]

HK 4035 13 turns in 1.4mm.
STSD winding technique
Winder: Modisc

[Clugh]

The windings style would be very useful in packing a parallel wye-delta machine. you have to have adaptability and single coil winding systems always give you that advantage, and there is no crossing wire in the slot leading to more crosstalk in the slot. The hairpin welds with silver solder would also actually cool at the nodes will almost 100 percent silver there fused to the copper. In a wide open body like a Cobra or real Scorpion Knocker it all fits with zero extra effort. If you leave the silver weld open the winding temperature will likely go down the resistance will be lower at these nodes if you weld it correctly. You can also finalize the connections easily with a circular high layer PCB with cooling vias and make it very short and compact lowering even more the resitance

[Clugh]

It was once read by me somewhere that a good rule of thumb was that the two conductors need to be able to fit side approximately the width of the slot opening. I also think that to get the most out of it the slot bottom has to sit the two wires side by side. If i match the slot opening to the same width as the slot bottom then that hammers protective over hang is good all the way to the slot bottom and you can wind ortho cyclic coils from the bottom to the top of the slot. It seems to me the hammer shout be thin versus think because is in nothing but a source of iron loss. You are always restricted by where you can lay the two conductors on adjacent teeth side by side. Any where you can only fit one wire you can steal that space for a turn but every were else the two conductor side by side restriction is in place all the way to the top of the slot. You can wind a 3rd level if there is clearance for the taller heads under the rotor. The easiest thing to do is shim the rotor out a bit to clear with the 500um precision shims. If you go too far you will change the Kv like shortening the stack.4

What we need is a square/rhombic conductor . That would allow maximum radial and axial fill.

I don't care how much you fill the bobbin in an orderly manner or the lack or airspace it leaves behind because factory wild winding have zero airspace to breathe so any orderly wind especially with a round conductor breathes better than a wild bundle in hand winding. Why not? The copper is also the heat sink in the machine no less.

Thank you for your time and patience,
Hubert

[Clugh]

I ordered 2 of these to dual 3 phase at 12 s lipo. They can do 180 continuous and burst 300. @ 40 grams inverter that's 320 continuous and 600 amperes peak into the big gurl.

[Clugh]

Lets see what we can do with this big gurl wrapped with a spaghetti noodle.

[Clugh]

LOL! You mean you dont know and claimed you ran it already Ralph?....


So your pretty winding on the 4535 14 pole scorpion only had a speed stiffness by shcmiddys chart of 75%.

I guess I can see why Tareq Alsaadi didn't want his name attached to the powercroco 45 series 14 pole Scorpion and went with Xnova...


TTYL
Hubert

[Clugh]

[Clugh]

I've an idea Dr Okon. How bout you record some motor constants and post them clearly in the forum for everybody to use in their calculators...



Io ?
Rm?
Kv?
Weight?

And please since you ran it at 18 degrees timing do not cheat!!!! make sure your idle current measurements are taken at that 18 degrees timing the same way.



Thanks
Hubert

[Clugh]

The outside transition wire holds the wire in place but it may be less effective there than at the bottom of the slot.

STSD winding eliminates the transit wire.

The second P650 black comp pyro for Mike P's TDR is complete and ready for termination..

We already shared the measured and recorded constants...


Hubert

[Clugh]

LOL! I guess this means no constants are coming . We do things differently here because I want real mechanical measure at this point and am building the device while you avoid the cals. In America if you ever paid attention to the winders on Heli freaks you'd notice they list the motors constants as a normal part of winding a new machine.

Refurbish? Ha! you mean totally restore. They wont bring alot on Barrett-Jackson....

[Clugh]

Btw I'm looking at the tron 7.0 dnamic. I was already looking at one then Mike just sent me this photo

[Clugh]

Hi Ralph
Its odd you hold up 1.9mm wire when you told modisc his 10 Awg 7050 2.58 mm was over the limit and anything above 1.8mm ended up loosing efficiency so will you post more about this machine????

Thanks
Hubert

[Clugh]

Achieved with the STSD winding technique.


So I guess the motor with 1.9mm you just posted only "breaks even."

[Clugh]

The best wound scorpion ever on a forum comes from Modisc. The 7050 is definitely in beast mode. We know from your post about it to him and Dekker about his work that you're simply a hater Ralph.....

10 AWG is like winding a clothes hanger..... there was nothing to ever give but congratulations..... Multiple strands like your noisy untwisted bi filar winding stacked axially in the slot suffer proximity then.

Or do you want a cookie for the break even 1.9mm you will put the 5 dolla ball bearing in? you should take a look in Holle's calculator sometime what just 500ma less idel amperage does for efficiency. Out of balance rotors or anything mechanically off robs efficiency. 1 amp difference in Idle is significant bruder.

balacing the rotor and a high quality quiet bearing can certainly raise the efficiency of the machine. There is also shaft Triplen that will eat a ball bearing. 38Khz is right were cavitation occur in an ultrasonic cleaner. Put a ball bearing in one "to clean it" and its DONE!! The same thing can happen on the motor shaft.

you know itz inaudible to humans Doc.....


Hubert