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Brushless
Motor
Introduction
For this tutorial, I will be using Dynam E-Razor 450 Brushless Motor
60P-DYM-0011 (2750Kv). It is a Delta wound 8T (It means 8 turns )
quad wind.
The winding pattern described in this tutorial (called an ABC wind -
ABCABCABC as you go around the stator) works for any brushless
motor with 9 stator teeth and 6 magnets.
One coil of motor is completely burned
Definition of terms
First, obviously you'll need to remove the old wires from the motor.
Be sure to count the number of turns around the armatures as this
will give you an idea of how to rewind the motor. The direction is not
particularly important at this point.
You will also want to note whether it is Delta or Wye terminated. A
Wye terminated motor will have three wires going to a central point
called the neutral, which is not connected directly to a motor lead. A
delta has no such connection, just three motor wires. Often the
neutral point one WYE has a piece of heatshrink over it to keep it
from shorting to the stator.
Our motor is Delta Connected.
Removing old coil
Starting the rebuild
Ok, now to rewind. First you must choose the number of turns you
want. My motor was 8 turns, and I liked it, so I'm going to rewind it
with 8 as well.
Here 8 Turns means , 8 strands of enamel coted copper wire are
connected in parallel which is wound on stator pole 8 times.
Here 36 AWG copper wire is used.
Rule of Thumb - less turns is a hotter motor and will yield a higher kv
and current draw. Go too low on this, however and the motor may not
run as the speed control may not detect the motor's position.
You'll also have to choose whether you want a Delta or WYE
termination.
We are using delta connection as it was factory default.
Getting winding Pattern
Now you need the winding pattern. This motor is an 9N6P (9 stator
pole, 6 magnet). Therefore the winding pattern is ABCABCABC (each
wire is wound every third tooth). This winding pattern will not work
with the very common 12N14P motor.
So before you start winding, count your magnets and stator poles and
determine the winding pattern from the list below. Lower case letters
indicate winding that tooth in the reverse direction.
9N6P-ABCABCABC
9N12P - ABCABCABC
9N8P (very rare) - AaABbBCcC
12N14P - AabBCcaABbcC <or> AaACBbBACcCB (I find this winding
easier)
Winding Design
Ready for another set? Start with a new wire on any other pole and
repeat the above process. Make sure to test for shorts after each
phase.
You'll notice the stator becomes crowded very quickly. You can clear
some room with a dull object such as a credit card.
Dont forget to tag other winding start and end points.
Rewinding in final stage
Connecting windings