So here’s we hardwire Hall sensors! Yesterday, I wedged them in place just to check for spatial sanity. I followed the placement up with a drop of superglue to hold the sensors in place for soldering.<\/p>\n The leads were cut flush with the end of the stator laminations. Then I point-to-point connected the VCC and GND pins of each sensor with Kynar wire-wrap wire (my favorite for making quick P2P connections, and which I had commissioned a restock).<\/p>\n In a standard LRK motor, 120 degree Hall sensor phasing results in an actual 120 degree sensor arrangement. With other winding configurations, this could be untrue – sensors could end up in the middle of teeth, for instance. Stretching a wire all the way around the motor to accomodate true 120 physical degree sensors is kind of unwieldy, so the next best option is to flip the center sensor<\/em> and place it on the direct opposite<\/em> side – which really means right between the other two sensors, convenient for wiring.<\/p>\n As I investigated when building FVM<\/a>, 60 degree sensor spacing with the center channel inverted is equivalent to 120 degree sensor spacing.<\/p>\n Using some 6-conductor flat insulated cable, I connected VCC, GND, and channels A, B, and C.<\/p>\n But wait – that’s only 5 pins. I just declined to use 1 of the conductors, but could see this being a thermistor lead or something in the future.<\/p>\n After making the connections, I flattened everything out to discourage side plate rubbing, then dunked the whole mess in epoxy again, and left it to set under heat and tension.<\/p>\n Real motor builders would never use shady 5 minute epoxy, but I’m not a real motor builder, so it’s okay. After everything cooled down, I reinstalled the stator into the motor and terminated the sensor connections in a 6 pin header.<\/p>\n Originally, this was a 5 pin flat (single row) header, but I discovered the idiotic way that a 1\/2″ nut does not fit over 0.6″ of headers.<\/p>\n Oops. Off they came, and in their place, a 2 x 3 header row was installed. One row contains the sensor leads, and the other sensor power.<\/p>\n What’s left to do now but TEST! TEST! TEST!!???<\/strong><\/p>\n Well, first I had to check if the sensors actually gave valid outputs. To do this, I ran the motor off RazEr’s controller and viewed the outputs on the MITERS Scope-on-a-cart (like soap-on-a-rope, but much more hardcore).<\/p>\n After making sure the sensors were phased correctly, it was time.<\/p>\n![\"\"](\"\/pics\/death\/blades_69.jpg\")
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