Brushless motor for Vehicle

[Larken]

I'm building a large disk type brushless motor for a hybrid vehicle. Motorcycle or small car.
Anyone got any ideas on winding the stator coils, the metal for the laminations etc?

[DennisCNC]

A few months ago on eBay there were 10+ ac motors that were built in germany for Ford hybrid electric cars they were about 12x12x20 inch and made like 40hp and 10krpm. The price was under $700 if I remember correctly. They were aluminum and water cooled.

[HugeRambo]

The winding of the stator coils, once you have decided how much current you want to use, size the copper area for that. Then I think the most consistent way would be to make up a jig so all of the slot windings are identical and precise, that way you can keep the optimum geometric arrangement to fir the most coils per slot to get the mast flux you can out of it. After you have bent all the windings in a linear fashion, then bend them into place around the circular stator.

As for the stator material, if you could physically achieve the laminations in cast iron, great, but i think you would probably have to settle for thin mild steel.

[vger]

Since you say burshless, I am assuming permanant magnets will be on the rotor. As HugeRambo said, a jig for winding will be a big plus for consistancy and precision. Lamination material could be had from transformers taken apart, the trick will be finding the correct transformers. Not ferite core transformers.

Good luck

[Larken]

Thats right, the magnets are on the rotating armature.
My prototype will have about 12 magnets on each side (dual side drive) and 12 coils.
Probably get the laminations laser cut once i get the material. Wonder what grade of steel works the best.

[HugeRambo]

Double sided motors sound like it will take a lot of thought as to the arrangement of the stator windings to make sure the are balanced between the sides. Also remember that you have to get the heat out of the stator somehow, and i have seen that it is hard enough to do passively with a thick aluminum plat on the back of a single sided motor. I have heard of someone demagnitising his strong rare earth magnets but allowing the stator to get to hot, with just a 1mm air gap between rotor and stator.

As to the material of the laminations i can't help you with a grade of steel.