DIY Winding a Brushless BLDC 12 kW Motor

[@jigarpurohit1189]

Hello Sir, Can you make a video for how to choose no. of poles, no. of slots and no. of winding turns as per our requirement?

[@justiceforsethrichwwg1wga160]

Your videos have inspired me greatly! I hope to build a solar velocar with a small tow behind camper trailer...still working on designs and waiting to get a few more tools before I jump in. My ultimate goal when finished is to travel from Oregon to Florida while camping and fishing my way there!

[@jaycal1920]

3:40 for such large soldering jobs you can use a small butane torch. Thie would have melted the wire lamination as well.

[@victoryfirst2878]

How did you come up with the multiple wire winding ratios ??? Thanks for your help Sir.

[@danb37]

I really need to build a custom electric motor with low rpm and good torque. Thank you for this video!

[@mackk123]

Thats the holy grail of motors lol maybe a geared motor or worm gear motor. The windshield wiper motors from cars are pretty cheap if you scrap them from a junkyard. 12v and also very torquey, not extremely fast but hey slow and with torque

[@polymetric2614]

You'd be easier to hear if you transmitted this by AM radio.

[@aifirm2566]

hahahahaha! pre amp hiss for days

[@manudehanoi]

you need insulation between the core and the wire. Enamel is very thin and with short on the core for sure without insulation

[@forschungsbuero]

Thats true! There are some black plastic parts to cover the stator. You can see them if you look closely.

[@minibanglades]

Hi sir. Really nice job. I'm new in this field and I 'd like to know how you measure the length of the copper wire in order to know that's going to be sufficient when rolling it on the coils. Thank you very much in advance.

[@mihailucian409]

Hello! Why have you used several wires connected at a time instead of one while winding? Thank you

[@lucal6166]

to get a certain torque out of a motor you need a certain total cross section of copper to be wound around every tooth, but winding one very thicc wire is difficult and doesn't fully fill the space between the teeth, so instead we use more smaller diamater wires connected togheter in parallel to achive a similar, equal or larger total cross section of copper

[@victoryfirst2878]

I am wondering if you would use Lintz wire to really raise the performance level of the motor. Just an idea that might really help you out with your project.

[@mohammadhashemi1771]

Nice work, can you please tell me what gage wire you used and what's the total length of the wire?

[@vincentbosire4332]

This is excellent bro, great knowledge, have it nice

[@vincentbosire4332]

Will you mind if I ask you something...?

[@bocksao]

For that part of action at 2:58 normally i use a torch and go outside because of the produced smoke. Nice work at all... for biking or flybike?

[@forschungsbuero]

This motor is driving the propeller of my Skyrider One: kzbin.info/www/bejne/eZCmpp6Jr9mmlbs

[@sezeryuksel6191]

Great video. Impressed with your skills. If I want 1000 rpm max on this motor what kind of winding would you recommend?

[@fuatgezgin818]

Senin sayfandaki videoyu izledim.Çok çılgınsın, sağlıklı yıllar dilerim

[@msghighway]

Hi Fantastic your engine, I would love to build one like this for an electric vehicle project Do you have a project for sale?

[@nathanallen6411]

Hey how is your project going? I’m designing one as well. Available models are expensive.

[@ianoiano3660]

Hello, great explanation! Can you please tell me where to buy part for this assembly?

[@forschungsbuero]

The motor is HPD13 from Geiger Engineering, Germany.

[@lemontea2065]

How much does your 12 kw motor weigh? And how much did the stator and the rotor cost?

[@1two299]

Да не будет там 12 кВт ну никак и при любой длительности импульса. Хватит ловиться

[@mikeyamaro9035]

Don't forget to say thank you lol

[@RobertSchmitt-u7l]

All should have amorphous core rotor stator, n55 magnets and gan switching. Will improve torque and range by 20 percent.

[@antoniomedina6445]

Congratulations amigo, buenas noches amigo mi nombre es antonio soy de venezuela, por favor que videos me recomiendas para aprender a construir motores electricos como el que construistes

[@abhivyas11]

What is gauge of wire and how many turns on winding

[@FlyWithSergio]

Where can I buy the stator? Thanks

[@noutram1000]

Hi, can you post a link to where you get the rotor and stator components from please?

[@forschungsbuero]

It is from Geiger Engineering, Germany. You can buy the complete motor there, its called HPD13.

[@jasonraser40]

I am greatful for this video.

[@younishadidi5714]

Where did you get this rotor ? Is it for a specific machine

[@dustinsutton4282]

How many turns per slot also are you doing clockwise counterclockwise repeating?

[@forschungsbuero]

3 turns per slot. The correct winding pattern depends on slots and poles.

[@spacial-active-machines]

Super erklärt ! aber wo bekommt man die Rohteile gekauft? Strator etc.....wäre Schön wenn für die Komponenten ein Link zur Verfügung stehen würde. Ist das ein 48 V Motor? Will so einem Motor eventuell in ein Kart verbauen...

[@charleshanson744]

so, what do you think of the benefits of square wire?

[@salihkarahasanoglu7299]

hello can we use this motor for electrical car as hub motor

[@desvasan3555]

Pls share details or link where to buy stator parts

[@hirarajvasarnikar]

Can you tell me what types of Winding you have done 7 wires in one slot ?

[@Rafaeljotiar]

Yes it is complicated for some people.and I am one of them. Please do you have any drawing of winding ?

[@Realistis]

This looks fantastic! Could you please set the language to English in the video settings? Actually it is set to russian so captions don't work. Thanks :)

[@Diycanada560]

12kw is it the peak? Does it produce more than 10hp?

[@florh]

does it make much difference if you put paper insulators between the wires and the sheet metal, I notice that you don't make use of it.

[@karlsa6298]

Great video and consise explanations! Thanks for sharing. You are, to be frank, inspiring.

[@lorddarphyve]

Is it possible to make a spotless motor by hand?

[@olusijimark]

Where did you get the empty motor stator and rotor?

[@mintudoku9375]

Sir... wire winding i cannot understand.... or all is clock wise or clock wise next anti clock...

[@dongguanfreerchobbyco.limi3655]

FRC Hobby produce various kinds of powerful motors: 15kw 12090, 25kw 120100, 30kw 15470, 45kw 154120 and 50kw 202/80 motors, even 80kw 202/150 motors, wish we can work if have any projects.

[@КожеМяка-з2б]

Двигателем всех изобретений, являются изобретения на коленках. Уважительно отношусь к таким людям!

[@asabovesotabelow]

....intantly subscribed,,

[@VickyKumar-tj8nd]

Hiii, this winding is possible with machine.my stator has 5 wire and 11 slots each .then plz tell me about winding machine.

[@schliemanns2121]

wo haben Sie den Stator gekauft? where you bought the Strator?

[@forschungsbuero]

The stator is a HPD13 from Geiger Engineering, Germany.

[@r.c.m.1270]

Great job !! Congratulations. Only one question. What wire section do you use ??

[@adnanfarooq5025]

just a question if you can give me an answer i have the washing machine bldc motor how much it will draw power from 110volt single phase (canada) wall socket if i use it with vfd 1-3 phase converter ?

[@НатальяБархатова]

Please, tell me, how many revolutions per minute on the motor? please give a diagram of the motor windings

[@thenoobletlego]

Looks cool, couldn't hear a word.

[@banyumili7454]

how many wires and how many turn each slot please?

[@gymkhanadog]

Where in the world did you actually find a bare rotor?

[@fun_ghoul]

1:11 is a humble brag. :-)

[@nicolaaugelli1840]

How many poles ( magnet ) are there in the rotor? Tks

[@gianlucaaversa2722]

Hello, great job, very synthetic and functional, just a question, how did you calculate the total revolutions per coil with the total section of copper wires? Thanks, I hope you answer me, have a nice day

[@forschungsbuero]

I was using Finite Element Analysing.

[@whathefunctr]

Is this use 12 kw in hour or 12 hours ?

[@juanrf4781]

Hola amigo, me gustaria saver la configuración de embobinado y los sensores hall que lleva. ..saludos gracias

[@dayanandkasle5469]

Sir i have bldc hoverboard motor which is of 350watt 36volt for 800 rpm. Actually I want to rewind this for 18 volt for 200rpm what changes I need to do? Originally winding data is 27 slot 25swg wire with 5 in hand for 12 turn in each pole. Can u help me plz?

[@NSB25445]

Where did you buy the rotor and stator?

[@flamantadanco]

Nice work.About how many kilograms of copper wire should be for such a motor?

[@jasonraser40]

It's the driver itself that makes a brushless DC motor of ample size strong enough to create proportional electricity.

[@usertogo]

Where do you buy those stator packs? A link in the Video description could be nice...

[@bansheebandithot350]

That’s great that you can do that .👍🏻

[@Itsontothenext1980]

How many pounds or length of magnet wire, did this require?

[@nitrousman8882]

excellent project - would be very nice to share sources for rotor and stator blanks. From Aliexpress, the parts are cheap and the shipping is several hundred dollars :(

[@Tore_Lund]

Is there an easy way to calculate the length of copper wire to order for rewinding a BLDC generator? I figured out the cross section of the old coils, by counting the turns of 0,6mm wire they were made off, so I know the area and number of turns I can fit with the new wire, but how does that translate into meters of wire to order? With a square core and more winding layers it will need to be longer that simply the circumference of the core x number of turns. Is there a simple rule of thumb? The length I guess I need, is too close to spool length, so I risk needing to buy 1/3 more wire for the last phase. ( I could also make a test wind of two slots, and measure the length afterwards, before I order.) Nb.: guess this question is popular in the comments!

[@forschungsbuero]

The way I do it: I have a big spool of 0.58 mm wire (diameter) and normally I put a bunch of them in parallel (5-30), depending on the motor type. Then I make a test winding of two slots, measure the length, multiply with the number of (double-)slots I will have for winding and add the length for interconnections and lead wires. This is for one phase. I give some cm extra and cut them all the same lenght after winding. As a rule of thumb, you can calculate: (2*stator height + 2*tooth width) * number of turns per slot * number of slots * number of parallel wires. Then add some 30% extra. This is the overall length of single copper wire for the whole motor.

[@Tore_Lund]

@@forschungsbuero Thank you, that was how I ended up doing it: pencil and paper only got me in the ball park, so I wound two teeth to see if the copper would fit and I settled for a number of turns that could do it comfortably, even if some turns were less than perfect.

[@Jerome____]

Can you kindly give details such as the wire gauge, number of wires, turns etc. Appreciate it.

[@forschungsbuero]

For this motor I am using 0.58 mm wire and approx. 16 in parallel (not shure). This is a 36 slot and 42 magnet pole configuration with 3 turns per slot. I hope this helps.

[@aaalbert]

Wo kann ich einen Plan für die Wicklungen bekommen?

[@klausasow7562]

Please could you explain me how to increase the power to 20kw?

[@forschungsbuero]

One way is try to get to higher rpm (eg. less magnets, less number of turns). But this motor should drive a prop at 2000 rpm, so higher speed is limeted by the prop. Other way is to build a bigger motor (more stator length, more diameter)

[@R_Kh_]

HI! what is phase cable size? 6 mm2 or more?

[@biger5339]

haben sie auch ein Video über den BLDC Controller der über 20kw vorgesehen ist?

[@davidprock904]

How to make it so it can be powered on indefinitely and not get to hot / overheat

[@tanohack]

Very nice motor! I'm interested to see make this Bldc, where are I can found the planes, size and datasheet for making it?

[@forschungsbuero]

THX! I bought the parts from Geiger/Flytec motor, so no plans available. But my own motors and parts are in planning. New Infos I will publish on www.Forschungsbuero.de

[@mojalovaa1]

Hi Can you please share information with us how you are calculate number of turn , wire diameter and other info ?

[@erfindergeist4390]

Hallo forschungsbüro, ich bewundere Ihre Arbeit sehr, vorallem gefällt mir die Präzision mit der sie an ein Projekt herrangehen, die selbst mancher großkonzern beneiden würde... Ich möchte ein Projekt umsetzen in dem mehrere dieser Motoren basteln würde, wo kann die teile bestellen?

[@lemontea2065]

Hi. I'm new to motors. Could you give me a few tips on how to make a high torque (65-80 N.m.), low rpm (120-150) brushless outrunner for an e-bike which would run on low voltage (12-18V) and consume few watts (100-200)? Or is it wishful thinking to build an e-bike motor with such parameters? Can the motor stator and rotor be from plastic or alumnium, or do they have to be from steel?

[@forschungsbuero]

Before you start designing your motor, I suggest to get into theory first. Read some good books about Electric Machines. You should have a rough understanding of electromagnetics, otherwise you won't get any good results. Of course you need steel (or other magnetic material) for rotor and stator. For low rpm you will need big diameter and high pole count number. Keep in mind, that rpm ist proportional to voltage and torque is proportional to current. Both will change with the number of turns.

[@bireckable]

If you did for an electric bicycle that type of copper used, how many laps should I take and how many slots and magnets should I wear. Where could you see all that information? Your advice would be of great help

[@gotinvietcongtytnhh8348]

Hi, i am new to bldc motor too, would you please give me a tips or document on how to calculate the stator size, and the relationship between it and the saturation. Hope to get your reply soon

[@m.b.a5260]

Sir how you know this is 12KW? İ mean how calculate.

[@SedatARSLAN]

Great video. Thanks for sharing..

[@rayking8732]

Where do u buy rotor stator?

[@nippon2003]

GOD I NEED THAT BEAST!

[@LoganT547]

You can find motors just as good as that in washing machines like F&P, Whirlpool, Samsung and LG.

[@Rafaeljotiar]

Where can I find the drawing of this motor ?

[@paulmartin8051]

how did you calculate your kv value?

[@forschungsbuero]

Measuring rpm and voltage and then divide both. A simulation tool can also give you an estimation of kv.

[@joecash5544]

How much did it cost for everything?

[@christophercridlebaugh8965]

What ESC do you use

[@whatthefunction9140]

how did you make the laminated core?

[@forschungsbuero]

For this motor I have bought the rotor and stator parts. But I have made other motors completely on my own. Then I order laser cuttings of silicon steel sheets, eg. M270-35A. Of course, you have to provide a dxf file of the stator cut.

[@yakz9885]

where can you get the rotor and stator

[@slicktires2011]

Are the steel laminations expensive? Is it problematic to use other types of steel, other than silicon steel?

[@FandS_Time]

Hi where did you buy the stator and rotor? And great video I'm looking forward for your next video 👍👍

[@forschungsbuero]

Please see other comments. Next video about installing the Hall sensors is up now: kzbin.info/www/bejne/a3O7eWl9hZ2ghrc

[@nikson1520]

O rotor de máquina lava e seca LG parece com esse

[@sandeepkumar-pm6cc]

Sir can you please suggest any company name and link form where I can buy stator and rotor?

[@Timedrawer]

what's the wire diameter you used?

[@paugasolina5048]

wirklich saubere arbeit klasse

[@rudysmd7350]

For stator you can take from washing mchine and change magnet with neodium for stronger ...or take it from motor hoverboard 6-8 inch motor

[@nippon2003]

is that possible to design 10+ kw motor as an highschool student? I can learn how to calculate everything and can use motor simulation software. is that possible!!?? I really need to design a motor!

[@yasinerol3799]

Hello Is it possible to provide the coil winding diagram of the 48 volt 250 watt hub motor?

[@burningions]

any calculation sheet?

[@JF32304]

nice unit.

[@yakz9885]

were do i get the stator?

[@kiranparmar3223]

Dear forschungsbuero, I have question about patent. I am trying to learn more about BLDC motors, will build small proto type and interesting to use for my ebike project in the long term. I just wanted to know from you few details about BLDC patent, As per my knowldege BLDC motors have patents, may be I am wrong. Do we need to pay the royalty or need pay to the parson/company, who is owning the patent ? if we build the BLDC motors in house for the ebikes and selling, it to the customers. May be this is not right place to ask question. But wanted to know from all.

[@mimlomiani6949]

Could you please help me ? where can I buy stators like yours ? I have been rewinding many many BS motors for my Rc. planes for a very long time now, but I have always wanted to build my own big motor for Paramotor glider, but money has been some problem lately specially the Aluminium is very very expensive in Denmark, so I had to wait until the day ..:) Now I would like to wind a motor and I am in need of some rewinding maps or something to get me started for a bigger motor. Is it something you could help me with ? I will be Grateful... Thank's

[@erfindergeist4390]

Mimlo Miani I agree I would also be interested!!!

[@vermilionssj9081]

Hallo das Video hat mir sehr gefallen vor allem mal zu sehen wie man das so Zuhause machen kann da ich gelernter Elektoniker für Maschinen und Antriebstechnik bin (auch Elektromaschinenbauer genannt) und das Motor wickeln Professionell gelernt habe (Handwerklich) wollte ich mal wissen wie man das Zuhause so realisieren könnte. Ein wenig Inspiration für mein Projekt brauchte ich allerdings auch noch hahaha da das noch in den Startlöchern steht. Ihr Video hat mir gut gefallen, allerdings waren sie ein wenig leise das macht aber nichts, ich habe alles mitbekommen. Ich hoffe Sie verstehen Deutsch,da ich von ihrer Englischen ausprache davon ausging und ich zwar alles auf Englisch verstehe aber Englisch schreiben mir etwas schwerer fällt. Ps. keine sorge ich finde ihr Englisch gut nur merkt man das es nicht ihre Muttersprache ist.

[@Xx-xd3zo]

What gauge?

[@arunpr1823]

Sir can u mail me few more details of this project and where this parts can be bought

[@eko653]

How much cheaper is it to wind your own motor? In %

[@forschungsbuero]

Well, maybe 200-300% ? Prototype building is always more expensive than off-the-shelf products. Depends, how much laser cut and cnc parts you have to buy.

[@uddhavambavane8853]

it would be much helpful if you spoke a little louder or heard the sound quality before uploading the video. thanks for your effort. but the audio is not audible.