Insert Bearings Bearing:  Parts: Aluminum Bearing Carrier (backmount or tube type), ball bearings

Insert the bearings into the bearing carrier on both sides.  Take care that the bearings are pushed in straight, moving around the edges with light pressure until fully seated.  Do not force the bearings in place!

Install Shaft:               Parts: Rotor, Shaft

Step1:  Insert the shaft into the rotor from the inside pushing out.  Test fit the motor shaft and rotor in the aluminum bearing holder such that the E-Clip and washer just fit outside the back bearing. This will determine how much of the shaft protrudes from the rotor. Mark the shaft lightly with a file just where it exits the rotor, so you will know where to stop in step 3.

Step 2: Put a little Loctite inside the center hole of rotor.

Step 3: Insert the shaft from inside out until you see the mark on the shaft flush with the outside edge of the rotor. Don’t waste any time here, or the loctite may set in the wrong place…

Step 4: Wipe off the loctite overflow, and wait for 24 hours for the loctite to dry completely.

Winding:   Parts: Wire and stator.

Notes:

1.       The number of turns and direction of winding of 9 points of stator need to be the same.

2.       Multiple strands of wire should be wound side-by-side, rather than twisted.

3.       “One Turn” means the wire is crosses over the upper face of stator.

4.       The numbers of “turns” of winding will directly influence the KV value of motor, so it need to be decided before winding.

5.       While winding the wire, make it neat and tight. Be careful not to scrape the insulating enamel.

6.       To calculate the length of wire required per phase:

(Number of strands X number of turns X 2.76cm)+20cm

Our example here is “ 3 strands, 12 turns” winding.

So each wire should have length of (3*12*2.76)+20= 58.76 cm. Just use this length and fold twice to cut for 3 wires for equal length.  

8. Orient the points protruding from the stator toward yourself.

9. After winding one turn, need to use tool such as slice of bamboo, ceramic screwdriver or any tool without sharp edge to press the wire. The purpose is to make the wire tightly stacked and left enough space for the last turn (winding C groups pole.)

10. After winding is complete, the free length of three wires remaining should be about the same. If not, it could be due to unequal turns of winding.

11. There are 9 poles.

We divide them into 3 groups:

1^st group:A1, A2, A3

2^nd group:B1, B2, B3

3^rd group:C1, C2, C3.

First, you wind at each pole then jump two poles. For example, you wind A1 then skip B1 and C1 and directly go to A2. Same as A3.

13 The wire could be wound in the clockwise or anticlockwise direction. No matter which way you choose, just keep the same direction.

Winding the A group poles:

1. Winding A-1

Keep loose end of 10cm. Hold the end and start winding. From the direction of the wire output, begin to winding from inside out.

After each turn of winding, use slice of bamboo, ceramic screwdriver or tool without sharp edge to press the wire and make it tightly stacked.

2. Winding A-2

After wind the first pole A1, the wire should go under the stator and wind the second pole A2 in same direction as A1.

3. Winding A-3.

Following the steps listed above. After finish winding A-2, skip 2 poles and wind A-3 pole following the same steps as A-2. Don’t forget to press the wire and make it neat and tight.  

Winding of A group poles are completed. 

Winding the B and C group poles:

Continue in the same manner as with the A group, skipping two poles after each pole is wound.

Soldering the wires:  Required: 30~40W soldering iron and sand paper

(Y Connection)