Building up the coils. Tigging?

timmyjane

I was looking at my coils and wanting to add a little more torque. Do y'all think I could get some magnet wire and make one or two additional wraps with 9awg and tig it to where the coils are already welded together to achieve additional copper without unwrapping and rewinding? Perhaps though it wouldn't work right and the current flow wouldn't be even. Just thinking out loud.

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timmyjane

I guess if you cut every coil loose and added that way it could work...
Anyone have an extra set of TXT series coils I could try on?

Volt_Ampere

That looks like coils from a series motor. Remember that the total armature current goes through these coils. Adding coils will give you more torque only if there is enough iron to support the additional flux.

JohnnieB

This is pure speculation, but I have my doubts whether the pole shoes are operating anywhere near saturation.

On the other hand, I doubt 9Ga wire will be anywhere near thick enough.

Ideally, use more of the same ribbon conductor to add loops to each field winding. (Salvaged form another series motor?)

Alternately, measure the width and thickness of the ribbon conductor, calculate the circular mils and use a wire gauge that has equal or greater amount.

I count 12 turns on ribbon in the coils, so each added turn should increase torque by about 8.3% theoretically, but I suspect it will be less than that because the lumps cause by connecting the added lengths will produce some distortion in the magnetic fields produced.

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It is an interesting experiment, but please be careful, a motor failure can take out a controller.

timmyjane

What would cause the controller failure?

Volt_Ampere

At full current, I suspect that the poles are near saturation. Motors are usually designed that way. Series motors run high field flux only at maximum current giving maximum torque there. Torque drops quickly as motor RPM increases and current drops.

JohnnieB

If the motor has a catastrophic failure and puts a dead short on the controller's output, the magic smoke may get released. The SPM and XCT families of controllers, and maybe some others, have short circuit protection, others don't.

When I exploded my stock PDS motor, it took the DCX controller to the Happy Hunting Grounds with it.

If something comes loose while the motor is spinning, there isn't much clearance and everything can get wound around everything else, causing a dead short.

timmyjane

C-
Im not nearly as versed as you are in this field so I will always take your advice. Any way to dumb your statement down to me. Ha. I'm thinking that you are saying the motor probably is giving all it can give due to the amount of iron in the armature. Currently my cart drops to a walking pace when going up a moderately steep hill. In my town we can use carts on the roads so long as the speed limit is 35mph or less. I would like to figure out how to keep up with traffic a little better when going up a hill The question I guess is how or is there anything more I can do to get that extra boost Im looking for. I have a full shop with just about any normal tool you can think of.

If the motor is giving all it can give why is it then that supplying more voltage to the motor increases speed and torque. I am currently pushing 48v on a 36v motor. Additionally what is done differently in a motor designed for 48v?

Volt_Ampere

In addition, each turn has more resistance and is further from the core so the effective increase is diminished.

JohnnieB

You are probably right, I was think more along the lines of the same pole shoes being used in multiple motor for production cost savings and the EZGO series standard torque motor using the same pole shoe as the and the higher torque motors from the same motor manufacturer.

The pole shoe meeting the torque motor requirements would work in a standard torque motor, so that might be a place the bean counter's bottom line argument would again override good engineering practices.

As you mentioned, the amp flow drops rapidly as RPM increases, so the pole shoe saturation would only be a factor at low RPM. However the torque gain would be throughout the RPM spectrum once the amp flow dropped below the saturating flow rate.