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Wrong way, Hal

A project log for A Wheel

Another Satisfying Single Wheel Terrifying Hoverboard Conversion

daren-schwenkeDaren Schwenke 09/04/2022 at 23:210 Comments

<edit>Or I can just swap the motors. That worked.

</edit>

Looks like I swapped the controllers from left to right as leaning forward goes back and vice versa, but hey... it powers on.  

It has some scary acceleration on that un-inflated tire, while reversed.  Heavy part in the front.  I can't imagine that would feel good to ride.  

This is only one hub/controller.

The math puts each hub/controller as contributing ~390 Watts with my 8S battery.  This is before any current sense modification to the controller boards.

Also, the controller boards seem to be fine with accepting and using the 33.6v from my fully charged 8S battery.  The original battery was 7S so there was a possibility that it could have over-voltage protection that could trip.  It did not.  Yay.  I wonder how high I could go?  I got room for another 4 cells if I could find them..

But.. there is another problem.

My hall sensor rotation has been flipped.

By flipping the shafts of the hub motors end for end I have forever changed the forward rotation direction.  This matters as the controllers only creep along in reverse.

Normally, just swapping any two wires on a sensor-less BLDC motor would reverse the rotation, but these motors have a hall sensor per phase and are fully sensored.  This allows perfectly accurate commutation at very slow speeds, but it also requires that the hall sensor position line up with the mosfet output.  

I can't swap wires.  The sensored motor only runs correctly in one wiring combination.  You can try the rest of the combinations without damage (briefly to prevent overheating), they just don't work.  No easy reversing of rotation with swapped shafts without swapping some hall wires at the same time I swap motor wires.  Oof.

Unless perhaps I cross the wires.  

Good heavens no!

Having the left controller power the right motor may just give us the anti-backwards molecular inversion that we require!

Wires... not... long... enough...  The hall wires are long enough, but the winding wires are just barely.. not.

It is a good thing I keep these assorted lengths of wire.  Have I shown you my assorted lengths of wire?

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