Magic Pie R.I.P .....maybe not! :-)

[o00scorpion00o]

 Yes it's finally dead. I brought it up mount Leinster today with the highest part of the ride 2400 feet. I drove to the car park at the base of the tv transmitter access road because I wouldn't have had the battery range to get me there and I wanted to get there and back fast, so I drove.

Anyway I started at an elevation of around 1600 feet and ended up around 2400 feet, all that was in just over a mile so you can imagine how steep it was, I will upload the trip details later.

It did well the steepest part saw the speed drop to 13 mph and by peddling I increased that to 15-16 mph. Max current was around 2700-3000 watts, I saw a max of 75 amps on the cycle analyst! The batteries weren't even been stressed with a continuous rating of 250 amps but I was pulling 2700-3000 watts most of the time which was generating more heat because it was well out of it's efficiency range and most of the power was going in heating the windings.

When I got to the top it was quite hot so I rested there for a few mins and made my way back

I think the problem was using regen on the way back down which only added to the heat that was already there. Because it was only at the end that she died!

To be sure I should have went up at lower power but parts of the climb were so steep I could barely do it
without full power!

Does anyone know where I'll get a stator rather than a full motor?

Mark

[DirtyGinge]

under 5 is fatal for motors on steep hills, as the phase amps get crazy ......

why not just get some laminated copper and learn to rewind ...then you can rewind the motor for more speed or torque depending on how many are already there ............have you opened  it up to see the damage ?

[o00scorpion00o]

Hi Ginge,

What do you mean by under 5?

I don't think I would have the patience for winding motors.

I haven't opened it up yet, I might if I get the chance tomorrow!

[DirtyGinge]

apologies, I mean under 15mph.......budweiser......

[o00scorpion00o]

apologies, I mean under 15mph.......budweiser......

HEHEH 

I'm on the old Sauvignon tonight! 

[o00scorpion00o]

I opened the Pie to my total surprise and found the windings to be perfect!





















I checked the halls and they fried, so I ordered new ones today should have them by Tuesday from the U.K Radionics!

Words can''t describe how shocked I am running 3 kw through this motor for 1.5 miles up 16% grade, I'm shocked I really really am, to say this is a good motor is an understatement!

Okay so I won't run it up there at full power any more, but I know it will get me to the top and if I let it sit long enough it should survive, or maybe just don't use regen on the way back down!

The Guys over at ES said a 16" wheel would have been far easier on the motor because it would require a lot less torque to haul me up there, but a 16" wheel is not practical for me because I like to cycle!


Mark

[DirtyGinge]

i think if you had the speed a little higher, you would have been fine.....maybe higher temp rated hall sensors and wiring should cut it......

[o00scorpion00o]

i think if you had the speed a little higher, you would have been fine.....maybe higher temp rated hall sensors and wiring should cut it......

Hi Ginge,

Yeah  considering it does 32 mph on the flat, I might actually need to give it more current, something to try, maybe that's what it needed!

[o00scorpion00o]

Here's the grade of the mountain the pie took me up!


Click to see full size.

[o00scorpion00o]

Still no halls, so I can't test to see if the motor works, they should be here today!

[MonkeyMagic]

Here's the grade of the mountain the pie took me up!


Click to see full size.

Holey LiPo !!!!!!!!!! No wonder it smoked lol you need titanium cased hall sensors for that haha

Now you should double your power and go sensorless And you know you have to conquer that hill now! Or should I say mountain?

[o00scorpion00o]

haha monkey, It did get me to the top! Just regen on the way down didn't allow it to cool, so that's what got it in the end.

I replaced the halls and am waiting for the high temp silicone to set.

From what I know sensorless is not supposed to work good with high power set ups, and I would have to get another controller.

[DirtyGinge]

lyen has a new version of the sensorless controller that should overcome these issues  ( ill let you know in 5 days)

Hey mark, my mac is RIP......after my first full mad journey to work, 25mph for 25 miles, the insulation melted in the axle taking out the green hall sensor....i spent a few days adding lipo, making sure the controller was cooled so I could go full power the whole way....oops....

So the dependable huge chunk of metal that is the pie has been refitted .........

I love the mac, but for sheer brute force for a long time, id have to swiss cheese the covers......

Ill fit that on my second bike, for maybe twice a week cycles with motor assistance

p.s. ( I have covered about 1500 miles on the mac, its not as bad as it sounds)

[o00scorpion00o]

Hi Ginge,


Your poor mac. I knew it was a matter of time before you killed it lol


Ginge I have no idea how that happened, 25mph isn't even beginning to stress the mac, that's only about 800 ish watts.

I can run 1200 watts 33 mph for 5-7  miles constant with some hills and the stock phase wires are barely warm.

It just doesn't sound right, the infineons cell-man provides for the mac are a perfect match, problems have been known with other infineons!

It should do well over 1500 miles!

The only thing I can think of is that you had the controller turned up to crazy high amps, but at 25 mph it shouldn't draw more than 800 ish watts anyway!

[MonkeyMagic]

Was that with the metal gears too?

Lol crazy Ginge on the Donkey (generally on 1 wheel)