Increasing power in hub motor by re winding

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bonospeed
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Joined: 09/29/2009
Points: 11

I am a new member to the EV community. I just purchased a 24v 500w brushless hub motor of Chinese manufacture, and I want to increase the no load RPM and power output of the motor. My plan is to rewind the hub commutators with thicker mag wire using less turns per point than it is wired to now. I borrowed the idea from RC builders who hand build BLDC motors using CD-rom drives. I will be replacing the controller with a Crystalyte 36-72v 20a. I am also considering replacing the permanent magnets with some stronger models. Has anyone here attempted anything of this nature? Any info about mag wire, BLDC wiring, or magnets would be great.
Regards!

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sixpax2k9
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Joined: 03/25/2009
Points: 285
Re: Increasing power in hub motor by re winding

I also wish someone would respond here as I would like to know as well !!!!!

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Dave ; Tennessee
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bonospeed
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Joined: 09/29/2009
Points: 11
Re: Increasing power in hub motor by re winding

I have found a better controller to use for my build. 24-48v variable with programmable logic very nice!

http://www.newkellycontroller.com/product_info.php?cPath=60&products_id=504

I am still looking through RC forums to try to determine what size mag wire to buy, but I think I will have to take the motor apart to know for sure. I have seen pics of BLDC hub motors taken apart with gear pullers, anyone check out what size gauge of wire they had when they cracked their motor open?

karma
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Joined: 12/18/2007
Points: 5
Re: Increasing power in hub motor by re winding

you still looking to rewind the motor. it can be done...

youtube

bonospeed
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Joined: 09/29/2009
Points: 11
Re: Increasing power in hub motor by re winding

Karma- That looks great! Any idea how much power it can take? I have my new Kelly controller running 35amps at 24v on my current motor and I am about to test it at 48v and 20amps hopefully no magic smoke will be released. I would recommend this controller anyone looking for a small power (250w-2 kw) programmable controller. I had some confusion with wiring and I received clear detailed responses from Fany at Kelly usually within 24hrs to any questions I posed.

marylandbob
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Joined: 06/22/2009
Points: 520
Re: Increasing power in hub motor by re winding

If the present windings fill the available space, it is better to leave the windings alone, and increase the voltage and amperage. A 50% increase in voltage can give about DOUBLE the horsepower, if your controller and batteries will provide the amperage. More ampere-turns gives more power! Leave the turns the same, raise the voltage to force more amperes, you will get more horsepower. With 1/2 as many turns as now, you would need double the current, at your present voltage, just to have the SAME horsepower you have now. Your top speed is limited by available horsepower, not winding inductance, as the RPMs involved are too low, even at double your present top speed. In RC car/plane motors, RPMs can be high enough that decreasing turns to lower the inductance DOES make an improvement with the low voltages used. As the voltage increases, it becomes possible to charge higher numbers of turns quickly, and current needed for a given power level is less at higher voltages, reducing resistive losses and improving efficiency. That is why the VECTRIX scooter uses 125 volts for its motor.-Bob

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Robert M. Curry

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