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-   -   Holmes Team, Pro, and Custom motor Tech (http://www.rccrawler.com/forum/holmes-hobbies/402585-holmes-team-pro-custom-motor-tech.html)

JohnRobHolmes 09-14-2012 07:45 AM

Holmes Team, Pro, and Custom motor Tech
 
http://holmeshobbies.com/skin1/images/Guido.jpg


This thread is dedicated for our continued tech and development into brushed and brushless motors. Many builds that start as customs will change existing models or become a new model fit for production. Enjoy the ramblings that keep me up at night!

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start:{greasy salesman pitch}

When you have a need for power that isn't satisfied by normal motors, choose Holmes! We guarantee the finest parts and construction techniques available for your needs. Our building team has more than a combined 45 years of experience. With podium spots and overall wins at state, regional, and national events worldwide- we have what it takes to take you to the top!

Our professionally crafted brushed motors begin with Japanese quality parts and USA hand winding / assembling. Armatures feature pattern winds with specific wire sizes to suit YOUR needs. Wind termination is reinforced using high-temp silver alloys (1000f+ melting point) doped with electrical specific fluxes. We use state of the art resin to impregnated coils, ensuring long term reliability. All armatures are precision balanced on our dynamic balancing machine and the commutator is diamond trued. We finish with hand assembling of each motor, taking great care to assure that every motor is aligned, shimmed, and constructed for best performance and quality.

end{greasy salesman pitch}

-------------------------------------------


I enjoy building and designing motors. It has been a passion in my life for years, and only gets stronger by the day! I REALLY enjoy custom tailoring motors for individual needs, even with off the shelf parts. Over the past I have had the pleasure to build motors pulling from a variety of “ideals” on what the best should be, giving motion to regular Joes and the world’s best drivers alike. I also have been very fortunate to engineer motors for a variety of customers in the Aerospace, Military, Weapons, Industrial Manufacturing, and Cinematography sectors. Thanks for supporting my passion, my life.


John Robert Holmes


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Looking to find these motors for sale? Contact us through holmeshobbies.com or check out our motor section! Holmes Hobbies / Holmes Bikes :: Motors :: Brushed

Here are a few examples of Pro Custom’s we have built, some of which become other brand lines down the road like the Team Flow or Team Crawl edition. Many times I will assist in selection of a motor that is the best fit, as the options can be overwhelming if you don’t already have a favorite build type. We can also fully customize any size motors from scratch: building the can, magnet layout, laminations (stator or rotor), and winding to suit the exact needs whether it be brushed or brushless. Although our business tends to service the R/C market in higher volumes, we can also build to suit any robotic or electric vehicle system that is needed.

Set of Team Flow motors for Multi time National champ Austin Dunn. I have hung out and crawled with him for years and knew exactly what he wanted before we even went back and forth. Big power, smooth control, but not too heavy. We could have gone nuttier in any direction, but sometimes a balance is the best option.

Skewed 3 slot arms, 30t medium fill, epoxy balanced
laydown brushes
Stage 4 Lightening
flux rings for on the spot tuning and emergency torque
Black rust preventative
5.5 ounce each

http://www.holmeshobbies.com/blog/wp...IMG_0004_1.jpg

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Another pair of motors built for National champ Turbofest. James wanted light, and was building a super light rig to match. He didn’t want hammer down power as much as lightweight smoothness. I chose the Team Crawl for him. Enough oomph to get going fast, but light and super smooth down low.

5 slot CrawlMaster arm, 13t medium fill, epoxy balanced
Standup brushes
Stage 3 lightening
Black rust preventative
5.5 ounce each

http://www.holmeshobbies.com/blog/wp...so-Stealth.jpg

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JeepSoHigh wanted a set of motors that were like a sledgehammer on course, but smooth enough to have great tactile feel down low. We went with a set of Team Flow motors for him as well, at this point the Team Flow was becoming an established build type


Skewed 3 slot arm, 30t high fill, epoxy balanced
Laydown brushes
Stage 3 kit
Blue hoods
Raw Oiled steel
“light” colors
5.6 ounce each

http://www.holmeshobbies.com/blog/wp...IMG_0012_1.jpg


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Eddie from Crawler Innovations also wanted something like a sledgehammer on course, but he wanted full torque and then some. Looks were also important, he wanted them looking sharp! Drag brake was a big concern for Eddie. He wasn’t very concerned with startup, so I had the chance to make him something a bit stouter in magnets. This would be like a modified Team Flow edition. He is the first person in the US to have FB12 magnet motors, maybe the first person in the world of R/C!

Skewed 3 slot arm
Laydown brushes
Orange hoods
FB12 magnets
“blacked out”
6.6 ounce each

http://www.holmeshobbies.com/blog/wp...IMG_0008_1.jpg


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We have many many other examples of custom and Team motors, and just like this hobby the hot items are always changing. Typically we only build 5 or 10 custom pairs per week, but they are always fun to build and it is very rewarding to help people get exactly what they want! Want to see something specific or have a set of Holmes motors to share? Feel free to post up! More to come as we build em and remember to photo em...

Some fancy heatsinked motors going to Japan. These turned out looking sweet!

http://www.holmeshobbies.com/blog/wp...IMG_0009_1.jpg

A more plane jane set of Pro Customs, all black with laydown hoods. Don't remember internals.

http://www.holmeshobbies.com/blog/wp...IMG_0002_1.jpg



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Now for a set of motors for ME!! I wanted light, without compromise. I wanted smooth startup, without compromise. I wanted the BEST motors available, which means nothing "off the shelf" would do. By the end of this project, these custom motors morphed into the future of the Puller 500 motor. There was no way I could make something like this without sharing!

Modified 540 endbell
Custom armature, "540" size
3000kv
n32 neodymium magnets, 75% coverage
Aluminum faceplate
Chromoly can
31.75mm diameter (regular 540 is 36mm)
4.5 ounces light

So how did it test? Startup is as good as our flagship model, the Crawlmaster. Can't get much better than that! Ok that is a lie, I have secret motors out there with better startup :twisted: How about light? A full 2 ounces less than a regular motor! That is a 1/4 POUND dropped off my XR10! Say hello to forward weight bias without increasing my rig weight :mrgreen: Power and torque were PLENTY as well, on 3s there is no point where I got close to stalling the motors and the pep is really amazing. The best part was how cool the motors ran during the many hours of testing this past weekend. After a 40 minute pack of just beating on them, they were very cool. Certainly much cooler than my 540s run!

So what was the rub? I could use a bit more drag brake on em, as could most people. We can either use Holmes Hold to accomplish this, or I can keep working on the design and improve it as we go forwards. I think I'll try to improve the armature and magnet layout. What else to do when my job is building motion control systems all day? "thumbsup"

540 on the left, Proto Puller 500 on the right

http://www.rccrawler.com/forum/attac...-v3-vs-540.jpg




Thanks for reading! I'll share more motors as we go along! I have 16 customs to wind up this morning, maybe a few will be fancy enough to share.

JohnRobHolmes 09-18-2012 07:42 AM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
Shown here is a set of vertically slotted armatures for a customer that wanted more low end pop and mid range power. Since this is for a crawler and not a racer we didn't go nuts removing material. The efficiency and peak torque stays high, we get the throttle feel wanted, and motor startup doesn't get unusable. A more aggressive and full length vertical slot affects startup speed to the point of being unusable unless we also weaken the magnetic field. Later today these armatures will finish the manufacturing process and be assembled into motors.

The option is available within our easy to build Pro Custom 540 Motor Holmes Hobbies / Holmes Bikes :: Motors :: Brushed :: Holmes Pro Custom 540. There is also angled and horizontal slotting for those that don't want to worsen startup speed, but still want more power. As compared to a 4mm web armature, an angled or horizontal slotted 5mm web armature has much better startup while still having higher wheelspeed and power than normal.


http://www.holmeshobbies.com/blog/wp...otted-arms.jpg

Scattman 09-18-2012 07:59 AM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
Me likey. "thumbsup"

Robotboy 09-18-2012 06:01 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
Very nice indeed! "thumbsup"

Mini 09-19-2012 12:33 AM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
Wow so many choices would want one of each :mrgreen:
Great stuff"thumbsup"

billj 09-19-2012 04:51 AM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
Quote:

Originally Posted by Mini (Post 3923933)
Wow so many choices would want one of each :mrgreen:
Great stuff"thumbsup"

What do u need motors for, you never crawl anymore:flipoff::lmao::lmao:

SVEN 09-20-2012 07:46 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
Got a chance to try out the Puller 500's in John's xr10 test rig at Nationals. I have been running Crawlmasters for a long time and the startup of the Proto Pullers felt just a smooth, maybe even smoother. Grab the trigger and the thing just begs to jump something.

Don't tell him, but when John went to go talk to someone for a while, I took the opportunity to use a good bit of his 1300 pack just to see how hot I could get the motors. Did a bunch of full throttle passes, donuts, and throttle stabs, but was unsuccessful in my attempts. The motors were barely warm. I was very impressed by every performance aspect of the Puller 500's.

JohnRobHolmes 09-26-2012 03:50 AM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
1 Attachment(s)
Quote:

Originally Posted by Scattman (Post 3922386)
Me likey. "thumbsup"

Thanks!

Quote:

Originally Posted by Robotboy (Post 3923370)
Very nice indeed! "thumbsup"

I appreciate it!

Quote:

Originally Posted by Mini (Post 3923933)
Wow so many choices would want one of each :mrgreen:
Great stuff"thumbsup"

I'm trying to keep the options simple and self evident, but it is really easy to pile on the options!

Quote:

Originally Posted by SVEN (Post 3927046)
Got a chance to try out the Puller 500's in John's xr10 test rig at Nationals. I have been running Crawlmasters for a long time and the startup of the Proto Pullers felt just a smooth, maybe even smoother. Grab the trigger and the thing just begs to jump something.

Don't tell him, but when John went to go talk to someone for a while, I took the opportunity to use a good bit of his 1300 pack just to see how hot I could get the motors. Did a bunch of full throttle passes, donuts, and throttle stabs, but was unsuccessful in my attempts. The motors were barely warm. I was very impressed by every performance aspect of the Puller 500's.


Thanks for the review and comments Sven! I'll go through a few more protos on the Puller 500 before committing to a design, but so far they are performing pretty dang well I must say.

"Somebody" wanted some custom motors for a top secret project, and off the shelf armatures just won't cut it. So I started modeling up the magnetic circuit since I couldn't sleep. Basic square circuit at first so I can judge the flux intensity at 20 turns and 50 amps. Now we start shaping the head and setting airgaps and back iron thickness. Fun stuff designing from scratch! "thumbsup"

JohnRobHolmes 09-27-2012 11:41 AM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
1 Attachment(s)
Another armature we are working on, this time for my team drivers. This is the stock Crawlmaster armature. Even though it took first place in 2.2 Pro this year, I know that it can improve greatly. I won't reveal how though, that's my secret! Dare I strive to match the TorqueMaster in torque? :mrgreen: At the least it is a good brain exercise and will get me back in the swing of Maxwell's equations.

vader2728 10-01-2012 09:21 AM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
Email sent...

JohnRobHolmes 10-01-2012 02:39 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
1 Attachment(s)
Got it, I'll send one back tomorrow when I get to my email computer.

A great start to some custom arms for my competitive drivers. Not only did they pull first place in every class at comp nats this year, they got first in all the Scale classes too! I owe them some work!

First step is to take out the "hot spots" where it saturates first. Second part is to bump up the ability to generate torque. Done and done.

Sagami lamination saturates at 90 amps in air. Holmes lamination saturates at 140a. When I get back home to a powerful computer I will throw some magnets and back iron into the equation and re-run it. I can only run one phase at a time (crappy computer) so the values will be lower with a fully energized arm.

A little shot of the Holmes 5p armature doing work, almost a full eclipse tonight!.

JohnRobHolmes 10-03-2012 03:21 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
This is a set of motors for a team driver that wanted smooth low end, but big drag brake, torque, and high wheelspeed. We opted for a set of Team Flow motors, built as customs in all black with upgraded magnets. FB12 magnets, 30t high fill wire, 10mm comm, XX springs, silver brushes, and alloy hardware rounded out the build. We will be changing both Team Flow and Team Crawl to FB12 strength magnets when the next shipment of parts arrives.


http://www.holmeshobbies.com/blog/wp...-Team-Flow.jpg

JohnRobHolmes 10-05-2012 03:09 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
FB12 magnet cans are available with complete motors through the Pro Custom motor builder! Right now they are a $15 upgrade, only 7 cans are left. In 8 weeks we will have a large supply and the price will fall to a $5 upgrade.

Manning 10-05-2012 05:31 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
What does the FB12 magnets do to the startup? Is the effect any different from the 3 pole to 5 pole arms?

JohnRobHolmes 10-05-2012 05:46 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
It makes the startup a little harsher. Decreases the KV a bit too, 3% on everything I have measured. With a 5 slot it isn't very noticeable. On 3 slot you could tell, drag and brake goes up. The hold on a TorqueMaster arm is really strong. I've been building them up with skewed arms to negate the effect and give a bit of drag and torque back.

If you want performance, there is no reason to run a weaker magnet if startup is acceptable unless price is dictating otherwise. If I had my way all motors would be Neo magged, but the price point won't allow for all people to afford them.

JohnRobHolmes 10-05-2012 10:34 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
1 Attachment(s)
More work on a new armature, for my own rigs and driving team. Shown here is a magnetic representation of the current lamination shape, pink represents saturation of the armature at 80 amps. So of course I have to try it and beat it. Efficiency, torque, and brake will increase. Combined with Neo Magnets it will make one helluva motor.

team3six 10-05-2012 10:38 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
I'm getting Excited. and anxious

JohnRobHolmes 10-05-2012 10:43 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
10 weeks minimum on that little project, it takes a while to collect parts from all the various vendors.

team3six 10-05-2012 10:55 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
I hear ya there John. BTW, I damn well forgot to grab them Brushes from you at Champs.
I gotta order 4 motors from you soon. so I think I'll wait and see where this goes and get everything all together.

Quote:

Originally Posted by JohnRobHolmes (Post 3950504)
10 weeks minimum on that little project, it takes a while to collect parts from all the various vendors.


JohnRobHolmes 10-11-2012 01:17 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
2 Attachment(s)
The following set of motors is for multi-time National Champ J. Ripplinger. They are truly a custom set of motors. The endbell is machined and assembled from 540 parts. The can is made from chromoly. The faceplate is machined from aluminum. Setscrews for the can are stainless, and hardware to hold the endbell is 7075 aluminum. I populated the cans with N34 neodymium magnets with a special layout for best startup and low speed resolution. The timing rings are machined from fiberglass. Armatures were custom built for me by Sagami for prototype work. I wound them to just over 2500kv, a very peppy wind that is perfect for Ripplinger's style of driving. The pair of motors weighs 250 grams on the nose. A full 1/4 pound less than a pair of regular 540s! This motor is likely to become the Team Crawl edition Puller 500.

Many people have been demo'ing a very similar motor at USRCCA and Scale nats. They are very smooth driving, certainly worth the effort to build! "thumbsup"

helhedded 10-11-2012 02:52 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
Quote:

Originally Posted by JohnRobHolmes (Post 3959594)
The following set of motors is for multi-time National Champ J. Ripplinger. They are truly a custom set of motors. The endbell is machined and assembled from 540 parts. The can is made from chromoly. The faceplate is machined from aluminum. Setscrews for the can are stainless, and hardware to hold the endbell is 7075 aluminum. I populated the cans with N34 neodymium magnets with a special layout for best startup and low speed resolution. The timing rings are machined from fiberglass. Armatures were custom built for me by Sagami for prototype work. I wound them to just over 2500kv, a very peppy wind that is perfect for Ripplinger's style of driving. The pair of motors weighs 250 grams on the nose. A full 1/4 pound less than a pair of regular 540s! This motor is likely to become the Team Crawl edition Puller 500.

Many people have been demo'ing a very similar motor at USRCCA and Scale nats. They are very smooth driving, certainly worth the effort to build! "thumbsup"

Wow those custom motors have an impressive parts list! I'm anxious to put some of the new 500 pullers in my berg. Thanks for letting me run them at Nationals.. the speed and "pop" was unlike any motor that I've ever ran :shock:

SDS Customz 10-12-2012 04:59 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
Totally stoked to get them here and give them a shot, the little bit I got to drive them they where very impressive

JohnRobHolmes 11-12-2012 10:10 AM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
1 Attachment(s)
We have been plugging away at custom motors lately, I've been bad about updating the thread with all the cool goodies!


Here are a few Crawl Type arms we just finished up for a couple world champion drivers. These were wound with a little "twist" to help pack in more wire, along with a double wire. It isn't obvious in the pics, but the different termination allowed an extra 33% more wire on the 16t than typical without interfering with the commutator as would normally occur.

The 9t double (far left) along with the special termination allowed for a full 50% more copper than I had previously been able to fit :shock: This was borderline too much, there was one wire on the final pass that took a lot of encouragement to seat. It also has about 12% more wire than the 16t, but it did take about twice as long to wind and terminate. The 5 slot Crawl Type arms don't work too well with thicker wire, so using double strands will become standard practice for our "Team" motors where higher wire fills are standard.


You will also notice the kevlar reinforced wire. This is needed with the special termination pattern to prevent flyouts, as there is nowhere for the coil leaders to bond like on regular CrawlMaster type arms.


The construction of the arms was otherwise typical. We use oxygen free copper wire with 200c rated insulation. Wire termination was reinforced with a 650c high silver filler via resistance brazing methods with electrical specific fluxes to prevent copper embrittlement. A 200c rated resin was impregnated into the coils after winding. Then we dynamically balance with the finest German balance epoxy. Standard day at the office I suppose :mrgreen:


After we cut the comms they will get assembled into motors and sent out "thumbsup"

JohnRobHolmes 12-16-2012 08:39 AM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
Here is a little vid of a motor armature modification, machining the armature for rougher startup and more punch. Typically this is done before winding, but these winds were already sealed so there is no harm.

Machining a Custom Rock Crawler Motor - YouTube
<iframe width="560" height="315" src="http://www.youtube.com/embed/7gfy8O7wtIo" frameborder="0" allowfullscreen></iframe>

YoUnG_vErSiOn 12-17-2012 11:27 AM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
thanks JRH!! looking forward to the package!

JohnRobHolmes 12-17-2012 12:09 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
1 Attachment(s)
Got a batch of motor cans coming my way. Since these aren't actually a solidified brand, I'll call em customs

Puller 500 v4.6 (on the right) drops an additional 7 grams from the 2.xx designs. v4.5 (on the left) drops 3 grams. Both v4 designs reduce airgap by 50% to increase torque and brake. Up and coming v5.0 will be even lighter and have fewer parts for assembly, while boosting back iron to further increase torque and brake.

sylvainp42 01-02-2013 04:32 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
Quote:

Originally Posted by JohnRobHolmes (Post 3949835)
FB12 magnet cans are available with complete motors through the Pro Custom motor builder! Right now they are a $15 upgrade, only 7 cans are left. In 8 weeks we will have a large supply and the price will fall to a $5 upgrade.

Any news for the new fb12 cans ?

I'm ready to order 8)

JohnRobHolmes 01-03-2013 08:29 AM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
Last estimate was a shipping date of jan15th.

sylvainp42 01-03-2013 11:17 AM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
Let me know, anyway it's snow everywhere here so I can wait a little more :)

jacobflyin 01-03-2013 01:02 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
Quote:

Originally Posted by JohnRobHolmes (Post 4104345)
Last estimate was a shipping date of jan15th.


How do I get on this list "thumbsup"

JohnRobHolmes 01-27-2013 09:04 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
FB12 cans should be here within a few days! All 2013 Team 540s will feature the upgrade.



The number of custom motors built has not been reflected in the thread lately, we have been too busy working in the shop. Some notables, however...

JohnRobHolmes 01-27-2013 10:15 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
****** Mechanism Motor

This motor was taken on as a custom for a company. The needs were straightforwards in size, speed, and resistance. Imagine a super powered airsoft gun :twisted:


Meet Mr. Chunky, a 540 shelled motor with large rotor and Neo magnets. It will become the Puller TTC edition in product line. I produced an additional motor that will go into my Southern Buggy. More specifically I made a bunch of parts to test :mrgreen:

http://www.holmeshobbies.com/blog/wp...er-540-TTC.jpg


Bare motor and stock "540" can, it weighs 7 ounces and leaks 32mT. With flux ring and leakage 15mT it weighs 7.8 ounces, dropping the speed 8%.


Target KV was 700 to 900, terminal resistance 100 to 120mOhm.
First armature was 24ga 60t, 720kv and 140mohm, Fail.
Second armature was 22ga 50t, 833kv and 118mOhm. Pass
Third armature was 21ga 50t, 833Kv and 92mOhm, Fail but possibly higher performance

http://www.holmeshobbies.com/blog/wp...1/2820-arm.jpg

Small comm was used to allow better coil clearance. Try as I might, I couldn't keep a pattern at such a high turn count. Wire was still laid as neatly as possible still, not fed without care.

http://www.holmeshobbies.com/blog/wp...ermination.jpg


Termination is always done for best conductivity. We have custom formed silver/copper amalgams that range from 15 to 71% silver. Practice makes perfect, and I like to challenge myself often. The following pic is tying 16.5ga wire into a 7.5mm 5 slot comm. The tang just barely holds it, and rips off at the slightest mishandle of such beefy wire.


http://www.holmeshobbies.com/blog/wp...ugh-Anchor.jpg


These commutators are more delicate than similar 3 slots. There is not much room to work, and the power to melt brazing filler will explode the comm and wire if not tuned properly. Fat wire sucks heat from the joint, needing increased heat. But I wanted to try it on a whim to see how it did.


Result is a 2700kv armature, 6t with 16.5ga wire :twisted: Mild speed for the low turn count, starts up butter smooth, and it should have plenty of kick. In reality I could rewind it with a double or tripple and increase wire fill 2x, the fat wire doesn't conform easily. After terminating this, doubles would be a cinch!

http://www.holmeshobbies.com/blog/wp...-Crawl-arm.jpg

JohnRobHolmes 01-30-2013 02:37 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
1 Attachment(s)
Building a secret Shafty motor for some Team drivers :D


So they want light, they want torque, they want smooth startup, and they want drag. We could build a Puller 500, or we could build a motor with double the wire size at the same weight and speed. 28mm arm, short stack, neo magnets, plus some other tweaks to get us under the 5 ounce mark. Same diameter as a 540, but with a much higher drag and torque density. Startup is smoother than a regular 3 slot thanks to the perfected skew angle and magnet layout. Terminal resistance is also lower than the standard 540 for the same speed. Who says we can't have it all :mrgreen:

Secret Shafty arm on the left, regular 540 arm on the right. Who do you think would win in a tug of war :twisted:

bigstu 01-30-2013 03:27 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
Wow. Great work.
I am betting you dream of this stuff, when you do manage to sleep...

helhedded 01-30-2013 03:46 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
Quote:

Originally Posted by JohnRobHolmes (Post 4153316)
Building a secret Shafty motor for some Team drivers :D


"thumbsup""thumbsup""thumbsup"

Szczerba 01-30-2013 05:16 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
Very interesting. :shock:

Love all the tech and build notes.

JohnRobHolmes 01-30-2013 09:51 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
Quote:

Originally Posted by bigstu (Post 4153409)
Wow. Great work.
I am betting you dream of this stuff, when you do manage to sleep...

I have a notebook with about 15 more designs for R/C and just as many more for personal transport and industrial/ robotic use, I go through months where I dream constantly about motors. Lately it has been digital switch inductive bounce and bad tattoos that haunt my dreams :ror: I can't wait to show the next two brushless motors we are working on. While I wait for some parts on the 540 outrunners, I've been playing with 10lb robot motors for BIG crawlers.


After the next few brushed motor designs are proto'd I will start bringing out the custom lamination shapes. It is surprising how much information can be learned after building a few motors that would suck for crawling. Sometimes the best information is from the opposite motor. Case in point, startup on one type of 28mm armature is strongly affected by copper and iron saturation. The information was only learned after building an actuator motor for a private firm. They didn't care about low speed control, it just needed to make big torque when 12v was slammed on it. Old designs that I had considered useless because of uncontrollable startup have been revisited and determined to be useful at specific KV's and wire fills. Took a build that started up at 7000rpm and made it 3000rpm, a huge jump in controlability based on the information from an actuator. Made my week "thumbsup"

Quote:

Originally Posted by helhedded (Post 4153434)
"thumbsup""thumbsup""thumbsup"


Quote:

Originally Posted by Szczerba (Post 4153577)
Very interesting. :shock:

Love all the tech and build notes.


I've been trying to make the time to share my work of late, its just been really hectic. We have made very large changes and upgrades to the shop and are adding new machines to the floor. Moved a wall and added 19 feet of benches too. In the next few days/weeks I'll start spilling more motor tech, I built/bought a few new machines to gather information with.

JohnRobHolmes 01-30-2013 10:13 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
FB12 magnets are now a standard feature on all Team motors. I will have them available on the site individually tomorrow. It increases magnet strength 8% over FB9 grade, giving better brake and torque. More specific measurements on KV, detent, and stall torque changes will be made ASAP.

JohnRobHolmes 02-02-2013 10:34 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
A fellow crawling enthusiast is wanting best drag brake from a set of "540" motors. He didn't want to sacrifice startup, but was willing to take more weight. Three words: Airgap Flux Density.

This draws the design to two focuses, terminal resistance and magnetic circuit efficiency. The following data was used to select the best fit using existing motor designs. To compare magnetic systems easily, one armature and endbell is tested in many cans. V4 cans were tested with increasing thickness of the back Iron, and two 540 cans were tested.

Base type: Team Flow 540 Crawler
3 slot, 5mm web, skewed
30t max wire
Epoxy balance
15% silver termination
10mm comm
2.58oz armature with shim
xx spring
Holmes Standup Soft Copper brush


Can, RPM @3v, no load, motor weight
v4.1 4900 rpm 1.5a (5oz)
v4.2 4525 rpm 1.3a (5.32oz)
v4.3 4300 rpm 1.4a (5.62oz)
v4.4 4100 rpm 1.4a (5.92oz)

540 FB9 4800 rpm 1.4a (6.52oz)
540 FB12 4697 rpm 1.4a (6.53oz)



Keeping the armature and endbell static lets us test the permanent magnet system efficiency. Slower speeds = lower Kv. Kt (N-m/amp) = 9.5478 / Kv. Slower motors produce more torque per amp and generate higher voltage when turned at a given speed. Higher voltage induces higher amp draw. The primary effect of depressing motor Kv is higher peak torque, brake (drag), and efficiency. The secondary effect is ability to reduce turns for a given speed, which lowers resistance and increases power.

TLDR: Lower speed with the same armature is a better motor.



To analyze the data, we look at motor speed and motor weight. The slowest speed is "best", but it can carry a weight penalty. Comparing a regular FB9 540 to either the FB12 or v4.1 can isn't a big jump in change, less than 3% speed either way. It is small enough to question the validity without a larger sample size. But the weight is a solid 23% loss in mass. Weight isn't really a factor on these motors though...

Comparing the FB9 to the V4.4 weight is a 9% reduction. The change in speed is a 14.6% reduction. For any given rolling speed this increases the brake available during "drag" or dynamic braking since we did not increase armature resistance. To change any spec 10% or greater is very noticeable, so we have an easy winner for the "high drag" needs. Lighter weight is just icing on the cake.




Upon sorting this data, we have two choices. Stick with the slower speed and reap mounds of torque, or drop a few turns /add voltage to convert our gains into extra power too.

You can guess which way I'm heading :twisted::twisted:

JohnRobHolmes 02-06-2013 01:31 PM

Re: Holmes Pro Custom and Team Pro Crawler 540 motors
 
2 Attachment(s)
Set of Puller 500 Flow SLs for KevG. Lightweight! Full 540 Power!

v4 Puller SL can
35t Flow armature
7.5mm comm
medium wire
epoxy balance
modded CheckPoint endbell
Copper brushes
Silver (stiff) springs
Polished black oxide finish

Final weight, 8.9 ounce for the set!



We will receive beta production parts for the Puller 500 motor soon, which will allow us to go into regular production volumes instead of slow custom sets. We have also begun the process of tooling up for a custom brush and endbell design for Team and Puller motors. It will allow for fully sealed motors and smaller motor diameters, along with better motor life.


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