AussieJester was laughing because I thought (for some reason) that I was using a 100 amp controller by mistake. By the time I actually got out to the garage and took the controller apart to find out what I was running he was banned.
As it turned out I had set the 60 mph downhill speed with a 36 volt 40 amp controller that had
no modifications whatsoever. I was running it with 48 volts though.
It's true that I own a 100 amp 48 volt controller and was afraid I got it mixed up. (that was an error... I wasn't using it)
The "final realization" on the rewinds was about
brush spring pressure.
Man I wish I figured that one out a few rewinds ago.
Once you increase the spring pressure it reduces the brush heating and that keeps the commutator cooler. That's something no one figured out... so I just got lucky to have found a paper online about it. The stock spring pressure is too low for the extra power. Brush timing is another factor, but it's not as important as getting the spring pressure right.
So on the negative side, AussieJester, from your perspective you still have to explain how I was able to reach 60 mph (downhill, flat is from 45-50 mph) with only 40 amps.
(the answer is kind of obvious... it's all about aerodynamics, aerodynamics, aerodynamics
)
But it's good to be skeptical... never just take someones word...
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I went really conservative on this last rewind, so the speeds and power are down compared to some of the others.
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Getting Back To The AC Induction Motor
I honestly can't see it being popular like Safe appears to think it will be ;-S The other alternatives
are lighter, smaller, powerful, NOT 240v and look alot less complicated to setup...
I don't normally read things at Endless Sphere, but since I was consulted on some of the ideas in the process of this project going together I have added a link to it to watch.
Frankly...
I don't know... if the AC Induction motor can be the winner in the long run. There is a clear need for a low cost, low rpm, high performance motor and "in theory" the AC Induction motor has a lot of potential. I was kind of shocked at the 50 lbs that he's using for the motor. My motor will be about 10 lbs and is roughly of the same size as the Unite motors. I plan to really drive mine hard and do all the "hard work" of figuring it out rather than just buying stuff off the shelf.
It's good to see a first project working... but it's far from where I think it needs to go before people accept it as the correct solution.
The main goals are:
Eliminate the need for Geardowns.
Eliminate the need for Multispeed Gearing.
Adhere tightly to the 1000 watt / 750 watt Power Limits.
Remove the Inverter and Rewind the motor to Optimize for lower voltage.
Equal (or exceed) the best that any other technology can produce.
...it's a tough problem.