Modifying the Turnigy 80-100 Brushless Outrunner – Part 2

Continuing on: Modifying the Turnigy 80-100 Brushless Outrunner – Part 1

This is a picture of the rewound stator. As described un the previous post the stator is now wound for ~90 rpm/V using double 1.5 mm copper wire. To hold the windings in place I use some dabs of low temperature heat glue. This will most certainly melt if I would put 3 kW of power through the motor, but I will replace the heat glue with high-temp epoxy when I know that everything works.

Rewound stator
The stator has been rewound with double strands of 1.5 mm copper . The heat glue is just to hold the windings in place while testing. Before using the motor under heavy load, the heat glue will be replaced by epoxy.

The motor is wound as an Distributed LRK (DLRK) and terminated in Y-mode. Using the notation from the picture below, S1, S2 and S3 are connected to the motor controller and E1, E2 and E3 are soldered together inside the motor.

The DLRK winding scheme. I've connected E1, E2 and E3 together and use S1, S2 and S3 as phase wires for a Y-termination. The sensors are mounted between 1 & 2, 5 & 6 and 9 & 10.

In the previous post I used ATS177 sensord mounted in a bracket outside the motor. This didn’t work very well with the modified controller. This itme I will try SS441A hall sensors, which are more expensive but thats the sensor that is usually recommended on the Endless Sphere Forum. I will also try to mount the sensors inside the motor which I hope will  be more robust and better looking. The sensors are mounted between slot 1 & 2, 5 & 6 and 9 & 10. Which gives them 120° spacing. To hold them in place before applying epoxy I use the same low-temp heat glue and a little kapton tape.

Sensor in stator slot
The sensors is mounted between two teeth of the same phase on the motor, all three sensors are 120° apart. To hold them in place I applied a small dab of hot glue and some kapton tape (the brownish tape in the image)

When I tried this setup with the modified controller it still didn’t run in sensored mode which leads me to suspect that there may be something wrong with this controller. I didn’t have time to do any thorough investigations why but my next step will be to inspect the sensor signals on the oscilloscope and try the motor on my other controller which doesn’t run at all without sensors.

Continue to: Modifying the Turnigy 80-100 Brushless Outrunner – Part 3

2 thoughts on “Modifying the Turnigy 80-100 Brushless Outrunner – Part 2”

  1. I was wondering why it appears you have 9 turns when you said you were going to use 7 to get your desired Kv?

  2. Guys I think I will have some data to offer that might help when I can get a little time to create the external flux maps for a quadrant of the large Turnigy outrunner. A really good friend of mine got me one for my birthday!

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