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Author Topic: 2010 DS Agni Motor, brush carrier experiment.  (Read 1517 times)

Camresearch

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2010 DS Agni Motor, brush carrier experiment.
« on: October 22, 2015, 07:11:10 AM »

Since I have about a week left before my 2010 DS goes to the great trade in crusher, I have been taking my last chance to experiment with the Agni motor, before I never see it again...  Hence building an experimental brush carrier from what was left of the original BBQ'd carrier....I hope what I have learned can help others that still want to use a brushed motor like the Agni.

Agni never should have made the carrier just from Bakelite, good for high voltages and low current, crap at taking extreme heat, like that of an arc or of a melting pigtail, that is glowing under 100 s of amps, due to a momentary brush mismatch, due to contamination etc. 

In the picture you will notice the heavy copper wires that go into the carrier, to feed the new copper brush holder tubes.  Copper tubes wont melt and burn like the originals did.  This should avoid the pigtails and springs from taking too much current and melting and the  need for constantly matched brushes. The copper also acts as a heat sink to keep the brushes cool.  You will notice that I have used larger screws for the connections.  There is also the addition of two screw terminal blocks that are wired to the dual temperature sensors, the red for the Positive tube and the other is the Negative.  I have soldered where it was needed...

You can heat these tube with a butane gas torch and they can take it, try that with the original tubes and they burn up really quickly! The tubes carry the current to within 2 mm of the commutator slots, so the current only needs to travel through 2 mm of brush material to the commutator, that avoids heating.  The wider tubes than the original carry more air past the brushes to cool them and offer greater lateral support for the tubes.  It is using PMG Perm 132 motor's brushes that wear slower and offer a greater contact area than the originals.  The copper bit at the connector end of the brush, sitting on the pigtail is a spring retainer, pigtail guide and brush tensioner  (I have the bike for another week so I don't care how fast the new brushes wear out), They will also help to cool the brush directly via the pigtail.   If I had the bike for another month I would have experimented with adding an advance on the fly function to reduce current draw at all speeds...

Theoretically, this carrier should be able to handle double the amps at a conservative estimate, based on doubling the copper to the brushes but really, it should handle far more than that.  The brush carriers are demonstrably the weak spot in an otherwise amazing little motor, in terms of the power to weight for a KISS, system, not requiring any fancy electronics to make it all happen.  Had Cedric used a decent material and approach to the carrier design, this motor would have been able to take the real world application that it was intended for, without the high risk of premature failure..... It should have really been a sealed design too, as those magnets are just "magnets" to ferrous dust.

Cheers,
Cam
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Bikes owned, from present to past: NS 150 Honda, DS 2010 Zero, RZ 500 N Yamaha #2, CB 250 Honda, Ducati 69 single, GT 750 Kawasaki, RZ 500 N the 1st,  RD LC 250/350 Yamaha + other bits, Kawasaki 200 dirt, DT 250 Yamaha.  Also spent time with Ducati 600 and Moto Morini 250 V twins and others :D

Camresearch

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Re: 2010 DS Agni Motor, brush carrier experiment.
« Reply #1 on: October 24, 2015, 03:21:40 AM »

The spring retainers before forming.
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Bikes owned, from present to past: NS 150 Honda, DS 2010 Zero, RZ 500 N Yamaha #2, CB 250 Honda, Ducati 69 single, GT 750 Kawasaki, RZ 500 N the 1st,  RD LC 250/350 Yamaha + other bits, Kawasaki 200 dirt, DT 250 Yamaha.  Also spent time with Ducati 600 and Moto Morini 250 V twins and others :D

Camresearch

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Re: 2010 DS Agni Motor, brush carrier experiment.
« Reply #2 on: October 24, 2015, 03:23:14 AM »

The spring retainer formed and pressed into the tube... Now just a polish of the tubes and it is ready to go back in the motor.

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Bikes owned, from present to past: NS 150 Honda, DS 2010 Zero, RZ 500 N Yamaha #2, CB 250 Honda, Ducati 69 single, GT 750 Kawasaki, RZ 500 N the 1st,  RD LC 250/350 Yamaha + other bits, Kawasaki 200 dirt, DT 250 Yamaha.  Also spent time with Ducati 600 and Moto Morini 250 V twins and others :D

Camresearch

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Re: 2010 DS Agni Motor, brush carrier experiment.
« Reply #3 on: October 24, 2015, 05:00:52 AM »

https://youtu.be/z2U1Oi9Pmb8

An experiment to compare the old carrier material against the new design...

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Bikes owned, from present to past: NS 150 Honda, DS 2010 Zero, RZ 500 N Yamaha #2, CB 250 Honda, Ducati 69 single, GT 750 Kawasaki, RZ 500 N the 1st,  RD LC 250/350 Yamaha + other bits, Kawasaki 200 dirt, DT 250 Yamaha.  Also spent time with Ducati 600 and Moto Morini 250 V twins and others :D

Camresearch

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Re: 2010 DS Agni Motor, brush carrier experiment.
« Reply #4 on: October 31, 2015, 10:50:33 AM »

https://youtu.be/b4rwIr7ys7U

The experimental carrier being tested in anger.

Cam
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Bikes owned, from present to past: NS 150 Honda, DS 2010 Zero, RZ 500 N Yamaha #2, CB 250 Honda, Ducati 69 single, GT 750 Kawasaki, RZ 500 N the 1st,  RD LC 250/350 Yamaha + other bits, Kawasaki 200 dirt, DT 250 Yamaha.  Also spent time with Ducati 600 and Moto Morini 250 V twins and others :D

cec

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Re: 2010 DS Agni Motor, brush carrier experiment.
« Reply #5 on: November 02, 2015, 08:39:27 PM »

This is an awesome project.  I have an older Agni motor sitting around.  I may need to do something similar. 

C
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Camresearch

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Re: 2010 DS Agni Motor, brush carrier experiment.
« Reply #6 on: November 03, 2015, 05:20:32 AM »

I would love to pick up two dead Agni 95s and make a 190 dual armature, single shaft 24 magnet end grain aligned half commutator phase motor... Capable of transwarp 6, 260 Kph.... If a race team wants my help for a ttx I am available... I think we could win it... If you could provide the power for such a motor... Also with a copper carrier the smoke shouldn't get out....
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Bikes owned, from present to past: NS 150 Honda, DS 2010 Zero, RZ 500 N Yamaha #2, CB 250 Honda, Ducati 69 single, GT 750 Kawasaki, RZ 500 N the 1st,  RD LC 250/350 Yamaha + other bits, Kawasaki 200 dirt, DT 250 Yamaha.  Also spent time with Ducati 600 and Moto Morini 250 V twins and others :D
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