YouTube has a bunch of videos about the motor, mostly involving wind generators but some about rewinding and running the motor - the ones I just watched were not that helpful.

The magnets seem much weaker than the NIB ones that we get in R/C motors - is that correct?
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Australian 2015 Featherweight champion
UK 2016 Gladiator champion

This is a commercial mass production motor, so the magnets are just regular, super reliable, super cheap ferrite magnets. If you were to upgrade them to NIB magnets, they would be pretty insane.

Andrew (Totaly Recycled) and I did a couple of experiments with these motors around 10 years ago. His washing machine had one and we ran it through his 12v -> 240v inverter and an ampmeter, he tricked the washing machine door mechanism to allow it to work with the lid open and we both tried to hold the drum still when it started up for a spin cycle. Despite both of has swinging off it, it easily over powered us and started up, while drawing less then 250w of power through the inverter!
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https://www.halfdonethings.com/

I'm not surprised, its a beast of a motor. I saw a video of a German guy who used just the stator with a custom wind and a completely new rotor to power an ultralight plane - he estimated it was putting out 20KW Sticking one of those on an EV would be awesome.
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Australian 2015 Featherweight champion
UK 2016 Gladiator champion

quote:

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Originally posted by Nick:
I'm not surprised, its a beast of a motor. I saw a video of a German guy who used just the stator with a custom wind and a completely new rotor to power an ultralight plane - he estimated it was putting out 20KW Sticking one of those on an EV would be awesome.

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Well this guy has made an 11.5kw one out of wood, seems plausible a commercially manufactured motor could run at 20 with decent cooling. So much power!

(note to self, make small ev scooter soon)


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www.demon50s.com - Minimoto parts
http://www.youtube.com/user/HyzerGlen - Videoooozzz

The guy took all the plastic off and the leads to the windings looked about 10mm at least. http://www.youtube.com/watch?v=PXI5d0Aws0Y Its a very professional build.
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Australian 2015 Featherweight champion
UK 2016 Gladiator champion

Sweet, I've never seen them stripped down like that...
Think I might have found myself a cool project!
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https://www.halfdonethings.com/

I'd try to find one of those LG motors, they look much easier to convert to a really hardcore out-runner. Compared to the outrunners we use, the large diameter looks relatively easy to rewind; search YouTube for several demos.
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Australian 2015 Featherweight champion
UK 2016 Gladiator champion

Gearbox fail:

Its been a bit of a frustrating week and now a VEX gearbox has totally failed . One of the 1st stage planetary gears has jammed on its carrier pin so badly that I needed vice grips to turn it even slightly:



The other three pins all have wear marks on the inside face and would probably have also jammed after a bit more metal had worn off. The gearbox was well packed with the same grease I have been using on the Banebots gearboxes so its not a lube problem. It looks like the carrier pins are a special cheese-grade steel and just not up to the job; I tried a test file on the top of one of the pins and the file cut very easily. The pins could be replaced, but I'm not sure if its worth the trouble.
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Australian 2015 Featherweight champion
UK 2016 Gladiator champion

Motor testing:

Here is a short demo of the Alien Power random reversing problem. In the video I am only starting the motor in the clockwise direction and you can see how the motor goes CCW at lower speed and then flicks to CW:

http://www.nswrfc.org/Nick/Reversing.mp4

Even at 1/4 speed its impossible to see a pause when the direction change occurs. When I substituted the HobbyKing in-runner motor, I couldn't get the reversing issue to happen, so its likely to be the motor . Time to contact the Alien Power dude.

Mr Mangle

I finally got the exact thickness of all the titanium sheets and spent yesterday tweaking all the CAD drawings. All four sheets were different to their advertised thicknesses and every single tab and slot had to be adjusted, not to mention many small misalignments that had crept in over the months of design updates.

More parts are getting made; a new motor pulley is finished and the wiring loom and electronics module are taking shape - the idea is to have enough parts finished so I can have a spin-up test as soon as the frame parts arrive in about three weeks.
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Australian 2015 Featherweight champion
UK 2016 Gladiator champion

Where do you get your titanium sheet/plate from? Also is it generally oversize or undersized and by how much?
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For my stuff
http://bodgeitandhope.blogspot.co.uk/

I get it from Titanium Joe http://www.titaniumjoe.com/index.cfm/products/sheet-plate/ in the US. The thickness is almost always a little bit more than what is listed. The stock list changes every week, so if they don't have a suitable piece its sometimes just a question of waiting.
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Australian 2015 Featherweight champion
UK 2016 Gladiator champion

"Well, there's your problem!"

I opened up the pistol grip radio and took out the trigger pot:



The pot is a specialist part with only 45 degrees of rotation and the resistance is less than half the value in the Spektrum radio. I had a look at the pots used in the Spektrum and they are 12K, 90 deg parts. After playing about with voltage divider equations, I can't find any combinations that give the required range of voltages, but I CAN find the equations to make an op-amp do what I want. Along the way I also found that a special type of chip called a 'rail to rail' op-amp is needed to get the required voltage swing. Just for once, RS Components has all the parts in stock and cheaper than ordering from O/S Who would have thought?

I will put together a test ASAP and if that doesn't work, there is always the digital option with a Teensy MCU.
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Australian 2015 Featherweight champion
UK 2016 Gladiator champion

Clean-up time:

All the parts for the op-amp experiment are here and I started breadboarding the circuit. Before that, I need to clear some space on the workbench:



I really need some serious therapy to cure my messyholicanism!

The CAD for Mr Mangle 2 is finished and off to Whyachi for waterjetting; the parts should be back in 2 to 3 weeks. I just realised that the Nats are really not that far off and I need to get cracking. Many of the internal parts are already made but there is still plenty to do if I want to take two bots to the event.
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Australian 2015 Featherweight champion
UK 2016 Gladiator champion

He he, my sanity has been restored with 80 little therapy sessions:



That was a great little afternoon project and has made quite a difference - I have not even half filled the draws yet. I packed in twice the storage space by mounting two sets of draws back to back on a lazy susan like this:



Now I just need some storage for tools and it will be fun to work on electronics again .
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Australian 2015 Featherweight champion
UK 2016 Gladiator champion