Type of wire for phase wires

General Discussion about electric bicycles.
Post Reply
ebike11   100 kW

100 kW
Posts: 1276
Joined: Nov 16 2013 8:01pm
Location: Korea

Type of wire for phase wires

Post by ebike11 » Jan 26 2020 7:40am

Hi guys
I have a cyclone mid drive and the phase wires are really short and dont reach to where I want to mount the controller. The phase wires arent that thick but they are quite stiff from the factory. Is it ok to use 12AWG silicone wire with xt60 connectors and connect them to the cyclone phase wires which already have xt60s soldered on them or do I need the stiff type of phase wiring?
Thanks

User avatar
spinningmagnets   100 GW

100 GW
Posts: 11527
Joined: Dec 21 2007 10:27pm
Location: Ft Riley, NE Kansas

Re: Type of wire for phase wires

Post by spinningmagnets » Jan 26 2020 8:24am

The 12AWG multi-strand flexible wire with silicone insulation is quite good as motor phase wire.

Image

Tommm   10 kW

10 kW
Posts: 715
Joined: Apr 03 2018 2:32am

Re: Type of wire for phase wires

Post by Tommm » Jan 26 2020 10:43am

Higher frequency favours multi strand wires. So the more strands the better for mid drive. Usually multi strand wires are softer.

markz   100 GW

100 GW
Posts: 8460
Joined: Jan 09 2014 11:38pm
Location: Alberta Canada

Re: Type of wire for phase wires

Post by markz » Jan 26 2020 3:54pm

Look into the Teflon PTFE wire, its durable but not as flexible. If I were rewiring the phase wires from the windings outward I would use that.

For your case study, any ole wire will do from Hobby Kings flavor to large big gauge speaker wire, 12g 10g etc

User avatar
MadRhino   100 GW

100 GW
Posts: 6115
Joined: Sep 03 2010 5:28pm
Location: Montreal QC Canada

Re: Type of wire for phase wires

Post by MadRhino » Jan 26 2020 7:01pm

After trying many, I have found that no wire does beat those that are stock on big hubs. If you want to upgrade, buy the wires from a bigger hub than yours. If you repair, use the stock wires. When you scrap a hub, keep the wires.

The closest match that I have found on the local market, is HALAR insulated aviation grade wire.
Make it fool-proof, and I will make a better fool.
Current bikes
Street: https://s20.postimg.org/ewrvugywt/Session_04_2015.jpg
Dirt: https://s20.postimg.org/lbqwr55ml/IMG_0157.jpg

HK12K   10 kW

10 kW
Posts: 606
Joined: Jul 24 2019 12:49pm

Re: Type of wire for phase wires

Post by HK12K » Jan 26 2020 8:21pm

Novice here, but if it were me and I were going through the trouble I'd be sourcing oxygen free copper with the highest strand count I could find. Oxygen free is less prone to oxidize in our hostile environments and the high strand count will help with flexibility as well as offer more surface area for the electrons to travel.

Silicone insulation is great for flexibility, but not so much for durability afaik. Maybe save it for inside the battery box and use something more robust for wires traveling on the exterior... unless you can incorporate conduit or other shielding into your build to protect it.

User avatar
MadRhino   100 GW

100 GW
Posts: 6115
Joined: Sep 03 2010 5:28pm
Location: Montreal QC Canada

Re: Type of wire for phase wires

Post by MadRhino » Jan 26 2020 9:26pm

Phase wires are silver thinned copper, multi strand but not so many, so they are pretty stiff. PVC Halar insulated, very thin and robust insulation to make the max copper size fitting into the axle channel and prevent friction wear.

After the phase wires are out of the motor, I like using a larger gauge, more flexible, Turnigy silicon insulated RC wiring.
Make it fool-proof, and I will make a better fool.
Current bikes
Street: https://s20.postimg.org/ewrvugywt/Session_04_2015.jpg
Dirt: https://s20.postimg.org/lbqwr55ml/IMG_0157.jpg

User avatar
Sunder   100 MW

100 MW
Posts: 2853
Joined: Sep 06 2011 11:24pm
Location: Sydney, Australia

Re: Type of wire for phase wires

Post by Sunder » Jan 26 2020 9:55pm

MadRhino wrote:
Jan 26 2020 9:26pm
Phase wires are silver thinned copper, multi strand but not so many, so they are pretty stiff. PVC Halar insulated, very thin and robust insulation to make the max copper size fitting into the axle channel and prevent friction wear.

After the phase wires are out of the motor, I like using a larger gauge, more flexible, Turnigy silicon insulated RC wiring.
^^ I'm with the Crazy Pachyderm. The cable that comes out of the motors are for a specific reason, which rarely correlates to "high performance".

I cut the cable as near the exit as practical, with a little slack for mistakes/changes of mind/slightly different future mounts, etc. Then use a much larger gauge turnigy silicon insulated wire. Unless your controller is really close to your motor, you want as low voltage drop as possible. Watts may be cheap by having oversized batteries, but volts you can't get back and it'll impact your top speed.
eBike: Q100H on 16S with Phaserunner FOC Controller
eMotorscooter: Vectrix VX-1 on 36S
eCar: Mitsubishi Outlander PHEV... Waiting for warranty to expire
eHouse: 5.5kw On-grid solar with battery backup coming soon!

After 5 builds, the best advice I can give, is start with high quality products. I prefer http://www.ebikes.ca

Post Reply