After sifting through page after page, I decided to turn to the experts...
I am in the planning / prototyping stage of converting a Mazda tribute into a ev. Two factor's have led me down the path im on, cost and what I get a kick out of and thats building from scratch. So I plan to design and construct my own BLDC motor and controller. I have the expertise in metal working and programmable micro processes to, i think, make this happen.
A few years back I constructed a much smaller BLDC motor (single stator pancake style, 6 coils, 8 neo perm. mags). The thing worked great for its purpose and I would like to modify this design to run this EV project, but having some problems finding information on adapting to the much larger design so here are some questions I have for experts out there:
I realize most of my questions are dependent on what I am looking to get out of this vehicle...and in all honesty its very simply knowledge, its a fun project for me to use to learn, but thats not gonna help you all answer my questions so here is about what I am thinking (subject to change):
-start with a 72V system and have room to go to 144V in the future
-not a race car, just handle my commute to work
-aprox 50-100 mile range (more would be nice, but I have to perspective on what that means battery-wise)
-budget: im doing it all myself and would like to see the motor and controller built for 2k or less
What gauge (or range there of) wire have others used in to make windings for EV motors?
(i dont care whether its BLDC, AC, DC) just looking for some perspective here.
Where is the best place to order bulk magnet wire?
What type of insulation should I get getting on that magnet wire?
(looking for what chemical coating and/or max tempuature ratings)
I have considered adding a 2nd stator to the other side of the rotor, any thoughts on doing that?
(i know how to do it, but is it worth it? are there inherent problems I am not considering, ect....)
What is the best way(s) to cool the motor
(the small scale I built didn't need anything more than a little turbo fan which might be a little awkward driving my EV down the road with a box fan zip tied to my undercarriage
Sorry for the length of the post, and I appreciate any suggestions, thoughts or anything other information related to my questions or just the project in general.