openinverter forum

Hi people!

Earlier, I met here somewhere an interest in industrial inexpensive motors for the purpose of reworking. but I didn't see the results.
Then let me be the first

an industrial acim with 4 kW and 8 poles (4 pairs) was purchased for the maximum size of the motor in the minimum power rating (this will come in handy later for the police). I decided to rewind the motor itself by making 2 turns instead of the regular 26 but increasing the cross section. the length of one phase harness was 10 meters. as an A/B sensor, I will use a special bearing to replace the regular one, it already has a built-in sensor for 80 pulses per revolution.

Interested to see you results, any pictures of the re wound stator?

Ev8 wrote: ↑Fri Oct 07, 2022 3:56 pm any pictures of the re wound stator?

in the second photo, two new phases have already been wound. the third phase I am winding right now))

in the future, I expect to connect this with the standard gearbox of an old USSR car and see if an industrial converted motor can be compared with a small Tesla motor (the dimensions are quite comparable, I have an even closer size in the ldu motor).
my phase cross section is now 21 square mm

Romale wrote: ↑Fri Oct 07, 2022 3:58 pm in the second photo, two new phases have already been wound. the third phase I am winding right now))

Sorry thought that was a before photo as you said you’ve rewound to 2 turns, it looks more

Ev8 wrote: ↑Sat Oct 08, 2022 8:07 am Sorry thought that was a before photo as you said you’ve rewound to 2 turns, it looks more

so after all, the winding is performed not by one wire, but by a whole group of parallel ones. )))

skf bearing in replacement of the regular one. The new one contains a built-in A/B signal encoder.
rotor length 120mm
inner diameter of the stator 160mm
I have completed a new winding. it remains to clean a lot of ends and make tips, tie the frontal lobes with a cord and impregnate it with electrical varnish.

does anyone know the dimensions of the rotor/stator of the SDU and LDU motor for comparison with this industrial one?

while the big motor is not ready, I decided to test the performance of the power module from Nissan note-e

what is your total number of turns per phase? Now I use an engine rewound by 12 turns per phase if I turn it into a star. as it turned out, this is a lot and the car easily eats 60 km per hour. this is 150 Hz. then there is a strong weakening of the field. If you turn it on with a triangle, the inverter does not pull it. Protection for 500 amps rms is triggered. the ends of 16 squares come out of the engine. and the battery voltage is 132 volts.

the number of turns 8-9 and an 800 amp rms inverter would suit me

yaroslav wrote: ↑Tue Oct 11, 2022 8:34 pm what is your total number of turns per phase?

it depends very much on the size of the motor, the diameter of the rotor and the length of the groove. also depends on the number of poles. my motor contains 48 slots for the wire and is eight-pole (4 pairs of poles), I wound two turns in one groove. only one phase contains 16 turns (8 coils) . I do not know how well it will go. I may have to redo it after testing.

yaroslav wrote: ↑Tue Oct 11, 2022 8:34 pm what is your total number of turns per phase? Now I use an engine rewound by 12 turns per phase if I turn it into a star. as it turned out, this is a lot and the car easily eats 60 km per hour. this is 150 Hz. then there is a strong weakening of the field. If you turn it on with a triangle, the inverter does not pull it. Protection for 500 amps rms is triggered. the ends of 16 squares come out of the engine. and the battery voltage is 132 volts.

By 150Hz you mean the best torque/power frequency or the weakening transition?
I remember i had this at 120Hz with LV winding and later on with HV i could extend it towards 150Hz. But i belive it was so because we wound it with a bit of lower RMS voltage in mind. This meand OI can be adapted in parameters settings. But if i stretched that frequency motor would become lazy in response.
Delta (triangle) winding is not advisable in a car. There is just too fast torque drop after innitial pull. Maybe if we could make this switchable during the drive we could have a launch gear and travel gear .

Romale wrote: ↑Wed Oct 12, 2022 7:22 pm it depends very much on the size of the motor, the diameter of the rotor and the length of the groove. also depends on the number of poles. my motor contains 48 slots for the wire and is eight-pole (4 pairs of poles), I wound two turns in one groove. only one phase contains 16 turns (8 coils) . I do not know how well it will go. I may have to redo it after testing.

It all depends on the supply voltage, the dimensions of the rotor are almost comparable to mine, 132 dimensions of 3 pairs of poles 960 revolutions and 54 grooves

arber333 wrote: ↑Wed Oct 12, 2022 7:36 pm By 150Hz you mean the best torque/power frequency or the weakening transition?
I remember i had this at 120Hz with LV winding and later on with HV i could extend it towards 150Hz. But i belive it was so because we wound it with a bit of lower RMS voltage in mind. This meand OI can be adapted in parameters settings. But if i stretched that frequency motor would become lazy in response.
Delta (triangle) winding is not advisable in a car. There is just too fast torque drop after innitial pull. Maybe if we could make this switchable during the drive we could have a launch gear and travel gear .

In fact, I already have a field attenuation of 100 Hz, but the car easily accelerates 60 km per hour, and the maximum speed turned out to be 90 km per hour, which is a little more than 200 hz, but for a long time

Here I took a video of overclocking

yaroslav wrote: ↑Tue Oct 11, 2022 8:34 pm Now I use an engine rewound by 12 turns per phase .....battery voltage is 132 volts.

how many turns do you have in ONE coil?

yaroslav wrote: ↑Thu Oct 13, 2022 4:30 pm Here I took a video of overclocking.....

which controller is used with this and can you attach your settings file? have you thought to raise the voltage twice at least?

yaroslav wrote: ↑Thu Oct 13, 2022 4:02 pm which is a little more than 200 hz, but for a long time

why not use more rpm/frequency and more gear ratio (ride the second one for example) ??
I plan to use a motor at 6000 rpm (400 Hz)

Romale wrote: ↑Thu Oct 13, 2022 9:03 pm how many turns do you have in ONE coil?

In one coil there are 2 turns in 3 parallels, it turns out 6 turns

Romale wrote: ↑Thu Oct 13, 2022 9:04 pm which controller is used with this and can you attach your settings file? have you thought to raise the voltage twice at least?

Controller with 12 mosfet IRFP4668, so the voltage will not be raised, they are only 200 volts.
I will publish the settings file later

On the second, it accelerates faster, but up to 40 km per hour, then sluggish acceleration

yaroslav wrote: ↑Fri Oct 14, 2022 7:07 pm In one coil there are 2 turns in 3 parallels, it turns out 6 turns

3 parallels?? and what is the cross-section of one wiring? it is difficult to wind a good amount of cross section with very thick wires

I have 2 turns of 28 wires made in one coil in parallel. the diameter of one wiring is 1 mm.