Hey LloydB,I have some ideals about building my own motor for a ev even though it is popular just to fork out the cash and buy one. I wanted to run my thoughts out to the public for a perspective other than my own on the subject. Here is what I was thinking about doing.
I was thinking about using sheet metal and make a plate diagram. Then cut a bunch of plates out using that diagram and sand the sides down on the plates to make ever thing nice and neat. Then taking those plates and stacking them to make my rotor. Then spot welding, braze solder what have you to stick all the plates together. Then wind the coils around the rotor.
Using sheet metal again and a spot welder, braze, solder what have you I would then make a stator and wind coils around that. I dont want to use magnets because I want this to be able to run at higher tempatures.
My only problem is I have to finish the design aspect of this and how all this would fit together. I want to be able to use more than one motor on the ev because I need to use a little more power.
I have some other ideals but am only talking about the motor for now. Does anyone know how I would go about completing a design for this mechanically and how to calulate the amps, torq, and voltage on this thing so I would now what size to of parts to use?
On the rest of this I would use basic metal working and basic sheet metal construction. Im not use to working with that kind of stuff but I would have to learn along way. Hopefully saving some money in the process.
Armature lamination thickness is like .018 or .025 inch thick. Core length maybe 5 to 6 inch. Maybe 49 slots. That's like 12,000 little rectangles to cut out while holding dimensions to .001 inch tolerance
After all that, I doubt you'll be happy with the performance. Better save up the money and buy a motor.