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3 hp conversion


By windy, Section Mechanical
Posted on Wed Mar 15, 2006 at 05:30:08 AM MST
More questions

I have a 3 hp Baldor high efficiency three phase motor that I am converting. I will be using the existing windings. I found the star connection and soldered the three extra wires to it. That was the simple part. My question is ,how do you figure how many magnets to put around the rotor,and at what spacing? There are 36 slots in the stator,no phase paper between the windings,and the rotor is 3 inches long and 4.5 inches in diameter. RPM is 1725.Windings are wired 2 in hand. From reading zubbby's post on his 3 hp conversion,he uses 60 3/4 inch disk magnets, 15 per pole. I think this motor is a 4 pole motor. Looking at the windings,I would have to say that the magnets should span 6 slots. Is this correct? Would a 12 foot blade be large enough for this size conversion? This is my first conversion so I'll have lots of questions for all the experts.

Thanks for the info!

windy                    

3 hp conversion | 8 comments (8 topical)

Re: 3 hp conversion (3.00 / 0) (#1)
by Ungrounded Lightning Rod on Wed Mar 15, 2006 at 07:03:33 PM MST

RPM is 1725.

That's your key.  It wants four poles (2 north, 2 south).

A two-pole motor at 60 Hz runs a few percent under 3600 RPM.  (60 hz * 60 sec/min.)  A four-pole runs half that (a few percent under 1800 RPM), a 6-pole runs 1/3 that (a few percent under 1200 RPM) and so on.



Re: 3 hp conversion (3.00 / 0) (#2)
by zubbly on Thu Mar 16, 2006 at 01:13:47 PM MST

hi Windy!

for a 4 pole 36 slot stator, the minimum span the coils can be is a span of slots 1 and 8, the maximum can be 1 and 10.  that was for a lap winding 2 cpoils per slot, 36 coils total.  for a concentric winding, it is most likely coil spans of 8-10-12, and likely what baldor uses, (18 coils total),  as long as it is a 4 pole winding (probably name plated 1725 rpm).

so for a lap winding of coil span 1-8, and a concentric winding of 8-10-12, the width of the mag should be the same as the width of 7 stator teeth. in either case, this will give you a mag that fits right between the coil legs.

use what ever mags you wish (i would suggest using 3/4 wide and 3/8 thick) to form the proper mag width and length. the length should be the same as the stator lamination thickness. you will also notice that the actual length of laminations in the rotor is the same as that of the stator. be sure to angle your magnets at 10 degrees to reduce any cogg to a minimum.  i find laying it out on paper and then taping the paper to the turned down rotor, and then centre punching the cross hairs on the paper makes a very accurate way to do it.

here is a link to the irc gallery that shows what i mean about laying your magnet arrangement out on paper.
http://www.anotherpower.com/gallery/zubbly?page=16

hope this helps,  have fun!
zubbly



Re: 3 hp conversion (3.00 / 0) (#5)
by drdongle on Thu Mar 16, 2006 at 05:09:26 PM MST

another power seems to be down
Carpe Vigor, Dr.D
[ Parent ]


stator drawing (3.00 / 0) (#6)
by wdyasq on Thu Mar 16, 2006 at 05:41:34 PM MST

Drawing shows mgnets, width and phase windings by color for 4 pole 36 slot motor.

Ron
Adventure is just bad planning." -- Roald Amundsen
[ Parent ]



Re: 3 hp conversion (3.00 / 0) (#3)
by vawtman on Thu Mar 16, 2006 at 03:34:30 PM MST

Windy I wonder If just 4 of Nothing To Looses #29 mags would be adequate.I dont think we need to fill the coil space entirely to extract reasonable power.



Re: 3 hp conversion (3.00 / 0) (#4)
by zubbly on Thu Mar 16, 2006 at 05:08:42 PM MST

hi Vawtman!

you are perfectly correct. even just 4 of the #29's would give you a unit that would work well.  not sure how output would be though. you may find that you could come close to using 4 of those 29's per pole.

i guess in the past i always made a point of stuffing as much mag material in there that i could looking for the max output i could get.

but you have hit a note there that has its benefits. if going for maximum mag in a conversion, you also need maximum prop also. for that 3hp conversion stuffed with mags would likely take a good 12 foot diam prop.  if you do not require max output, less mags, and smaller prop would suit many people just fine.  i think the greatest advantage then is that you would have a "very" heavy duty unit. just ball parking a prop using only 4 29's in it i think would suit a 6 foot prop well.  maybe 2 29's per pole would take an 8-9 foot prop.  (just guestimating).

i still have my 25hp unit to convert, and will need 48 of the 2x1x1/2 mags in it and propably a 25-30 foot prop.  output probably be an easy 10kw (what the heck do i need all that for?) so your thought on less mag is good. if i do the 25hp with 24 mags, the output would be plenty to handle most anyones needs, and i think a lot less scary with perhaps a 16-18 foot prop.

glad you brought this up!  now maybe i can talk some sence to myself ;)   lol!

have fun guys!
zubbly

[ Parent ]



Re: 3 hp conversion (3.00 / 0) (#7)
by vawtman on Thu Mar 16, 2006 at 06:08:24 PM MST

Zubbly,Why not let windy go ahead with the blades he planned.I think the motor would still handle the blades and not heat internally.Thats the nice thing about conversions.He would need to make sure the blades are balanced to protect the endbells over time but who cares for the cost.What do you think and how are you doing?

[ Parent ]


Re: 3 hp conversion (3.00 / 0) (#8)
by windy on Fri Mar 17, 2006 at 09:37:00 PM MST

Thanks for all the comments. It's all starting to make sense.

My first conversion started out with a 7.5 hp but I going to try something a little smaller. 400 dollars for magnets and rewinding might more the I can stomach. Making a 18 foot prop with no experience might be a receipe for disaster. Then there's the tower. Better to experiment with my 3 hp. Then I read about zubby's 25 hp! Good luck on that one.

windy



3 hp conversion | 8 comments (8 topical)
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