Direct Drive to Diff E Revo Build

[johnrobholmes]

It IS very difficult to determine what the KV will be before winding, although basing it from similar sized stators and magnet strengths does help. The hardest part is that every stator fill is different. I don't think I can have any more wire pushed into my stator, the 5 strands of 22awg is such a tight fit I have to thread some of the last winds in.


I kinda eyeballed the fit of my wire. Put in a chunk of strands and said "that looks enough". My math was that 40 strands would barely fit.

[sikeston34m]

Originally Posted by johnrobholmes

It IS very difficult to determine what the KV will be before winding, although basing it from similar sized stators and magnet strengths does help. The hardest part is that every stator fill is different. I don't think I can have any more wire pushed into my stator, the 5 strands of 22awg is such a tight fit I have to thread some of the last winds in.


I kinda eyeballed the fit of my wire. Put in a chunk of strands and said "that looks enough". My math was that 40 strands would barely fit.

That's an 8 turn motor?

An 8 turn factory motor is 988kv. Your motor's amp carrying ability should be better with a Total CSA of .020258024

Good Job! You beat the factory on fill.

[aqwut]

Originally Posted by sikeston34m

That's an 8 turn motor?

An 8 turn factory motor is 988kv. Your motor's amp carrying ability should be better with a Total CSA of .020258024

Good Job! You beat the factory on fill.

Maybe off topic.. Lehner won't fix my 2280.. you guys know how to rewind inrunners?.. my 2280 needs a new can or to be rewound..

[johnrobholmes]

Originally Posted by sikeston34m

That's an 8 turn motor?

An 8 turn factory motor is 988kv. Your motor's amp carrying ability should be better with a Total CSA of .020258024

Good Job! You beat the factory on fill.

Yeah, I went with an 8 turn so I could compare it to the 8 turn Wye I have from the factory. I still haven't finished the last phase, another 1.5 hours of winding.


If you want to get a ballpark for kv, a motor that is twice as long with the same wind count will have half the kv. Same formula works for a motor that is 1.5 times as long. As for wind count, the formula is really stinkin complicated so I'm not going to even attempt. When you change stator diameter it messes with things. When you change magnet strength it messes with things too.

[sikeston34m]

I've been making some progress winding the 3530 stator. This one will fit in the E maxx, so that is the platform I'll be testing it on.

Factory wind was 20 strands of 28Ga. at 5 turns. This yielded the following specs:

715Kv
Max Voltage: 30 volts (8S Lipo)
Max Amps for 20 seconds: 55 amps
Max Continous Watts: 1000 watts
Efficiency: 85%

In motor winding, the awg of the wire versus it's max. Amp rating tells that it is REALLY being pushed hard.

In the factory winding, 20 strands of 28 awg are rated to carry 28 amps even though the motor is given a 55 amp Burst Rating. See? This cuts efficiency and generates heat.

I am just dying to know how wye versus Delta Terminations perform. I know how the Delta performs. I've got a good taste of that. So with this wind, I'm working with 22awg wire. 3 Turns with 7 strands with a Wye Termination.

On my winding, 7 strands of 22awg is rated to carry 49 amps. In Factory spec comparison, this translates into right at 100amp Burst rating. Since amp rating are based on resistence, I feel good about this wind.

Here's what it looks like so far.



Yep, I'm using the Broom stick trick. I first lay out all 7 strands, tape one end, then I roll them up on the broomstick EXACTLY parallel, the way I want them to lay in the winding.

It really helps to pull the wires and make a nice neat radius to make the turn with.

As you can see, I've removed the bearings, installed a bolt with a couple of washers. I also numbered the poles so I can be SURE that I wind according to the DLRK diagram.

I clamp the bolt in a vise, wind a pole, then turn the stator for a fresh grip on the bolt.

[sikeston34m]

I can't imagine being a motor winder and doing this all day! LOL

Now to make the terminations.

[sikeston34m]

My first Wye wind. She's done!

What's even better is, it runs! Seems to be pretty smooth just running no load.

The Motor on the left is a Factory Wind.