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About 'small electric motors'-Electric Motor Winding Testing?







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About 'small electric motors'-Electric Motor Winding Testing?








My               Black               &               Decker               CMM1200               Cordless               Electric               Mower               was               slowing               down               while               mowing               the               yard               and               I               did               not               know               why.

My               initial               thought               was               that               the               motor               was               not               getting               enough               power.

So               I               ordered               a               large               dial,               analog,               50               amp               ammeter               from               Ebay.com.

The               ammeter               came               in               and               it               was               a               used               military               surplus               product               so               I               felt               a               little               nostalgia               right               away.

I               was               going               to               reuse               a               piece               of               instrumentation               that               would               have               otherwise               been               thrown               away.

Of               course,               mowing               with               the               installed               ammeter               is               real               fun               because               you               can               see               the               dial               sweep               back               and               forth               as               you               go               through               thick               grass!

Why               Should               I               Install               An               Ammeter               On               My               Electric               Mower?


               When               you               drive               a               car,               you               keep               track               of               your               fuel               consumption               by               monitoring               the               miles               per               gallon               (MPG).

With               electric               motors,               the               standard               measure               of               power               consumption               is               with               an               ammeter.

The               ammeter               monitors               the               amount               of               current               flowing               through               the               wires               in               your               electrical               circuit.
               Before               you               begin               this               project               take               extreme               caution               with               all               the               wires.

I               recommend               disconnecting               one               of               the               batteries               so               that               you               will               not               run               a               risk               of               turning               on               the               electric               mower.

Contrary               to               popular               belief,               a               healthy               person               without               any               heart               conditions               or               electric               implants               cannot               be               harmed               by               24               VDC.

My               concern               is               the               mower               accidentally               turning               on               while               you               are               moving               the               wires               around               inside.
               Remove               The               Black               Plastic               Top               Cover               
               Use               a               long,               flat               head               screw               driver               with               a               narrow               tip               to               remove               the               four               bolts               holding               down               the               top               black               plastic               top               cover               of               the               CMM1200               mower.

The               screws               are               going               to               be               a               little               hard               to               remove               because               the               bolt               is               designed               for               use               with               a               special               tool.

Since               none               of               us               have               that               tool,               you               have               to               make               do               with               a               long,               small               tipped,               flat               head               screwdriver.

Once               you               have               the               four               bolts               removed,               put               them               in               a               spare               coffee               cup               so               that               you               will               not               lose               them.
               Cut               The               Black               Lead               Going               Into               The               24               Volt               DC               Electric               Motor               
               For               many               of               you,               this               will               be               your               first               time               interacting               with               a               24VDC,               high               torque,               electric               motor.

The               frame               of               the               motor               is               over               six               inches               tall               and               solid               steel.

The               armature               is               enveloped               with               heavy               gauge,               solid               copper,               baked               enamel               wire               for               an               imposing               and               powerful               look.

As               a               result,               pulling               50               amps               of               power               with               this               metal               behemoth               should               be               no               surprise.
               The               black               lead               going               into               the               electric               motor               is               called               the               negative               pole.

The               only               important               rule               with               measuring               current               is               to               find               the               direction               of               the               flow               of               power,               not               the               polarity,               which               is               why               I               can               install               the               ammeter               on               the               negative               lead.

Prepare               both               newly               cut               leads               by               removing               1               inch               of               insulation.

You               should               exercise               extreme               care               while               doing               this               because               you               do               not               want               to               cut               any               of               the               stranded               copper.

Every               piece               of               copper               that               you               remove,               while               cutting               the               insulation               off               the               wire,               will               further               reduce               the               power               available               to               the               high               amperage,               electric               motor.
               Heavy               Gauge               Wire               Is               Critical               To               Accurately               Monitoring               Current               And               Running               The               Mower               
               Let's               not               forget               that               we               have               just               cut               the               negative               power               feed               for               the               cordless               electric               mower!

If               you               wish               to               keep               your               lawn               machine               operating               at               peak               efficiency               then               you               have               to               use               at               least               8               AWG,               stranded               core               wire               for               the               leads               running               to               and               from               the               new               ammeter.
               Placement               Of               The               50               Amp               Ammeter               On               The               Black               Plastic               Top               Cover               
               A               gap               of               3"               exists               between               the               batteries               and               the               bottom               of               the               cover               so               you               will               have               more               than               enough               room               to               sink               the               ammeter               with               its               attached               wiring.

Pick               a               location               on               the               cover               so               that               you               will               have               one               inch               or               margin               between               the               back               of               the               cover               and               the               bottom               of               the               ammeter               face.

Now,               draw               out               the               hole               that               you               will               have               to               cut               to               sink               the               ammeter               into               the               top               of               the               cover.

Use               a               Dremel               tool               or               similar               cutting               device               to               cut               a               hole               in               the               black               plastic               cover.

Once               complete,               drill               holes               to               accommodate               the               anchoring               bolts               and               attach               the               needed               bolts.

Make               sure               the               dial               faces               the               handle               of               the               lawn               mower               so               that               you               can               watch               it               while               mowing.

Finally,               I               used               some               black               silicone               sealant               to               create               an               air               tight               seal               for               the               guage               itself.

I               did               not               want               any               dust               to               get               inside               and               ruin               the               delicate               mechanical               parts               inside.
               Finishing               All               The               Wiring               And               Testing               Before               Sealing               The               Top               Cover               
               Get               your               soldering               iron               out               and               connect               3ft               of               8               AWG               cabling               to               each               of               the               cut               leads               from               the               motor.

Now               use               some               ring               connectors               to               create               a               smooth,               soldered,               oxidation               free,               high               amperage               terminal               for               the               end               of               both               of               the               wires.

You               will               now               simple               bolt               these               to               the               back               of               the               ammeter.
               Before               you               put               the               black               plastic               cover               back               into               position,               turn               on               the               cordless               electric               lawn               mower               first               to               ensure               that               the               wiring               is               terminated               in               the               correct               position.

You               will               know               it               is               working               if               the               needle               on               the               ammeter               hovers               around               8               -               15               amps               when               resting               on               a               sidewalk               or               similar               concrete               surface.

If               the               needle               jumps               below               0               amps               when               you               turn               on               the               mower               then               you               should               switch               the               two               leads               on               the               back               of               the               ammeter.

Once               you               are               sure               it               works,               pull               those               screws               out               of               the               coffee               cup               and               carefully               place               the               cover               back               into               position.

I               pushed               the               ammeter               wiring               to               the               left               side               of               the               battery               bank               since               this               area               has               no               existing               wires.
               Results               
               As               you               can               see               from               the               photos               provided               with               this               article,               the               ammeter               looks               like               it               came               with               the               Black               &               Decker               CMM1200               cordless               electric               lawn               mower.

As               soon               as               you               turn               it               on,               the               gauge               sweeps               over               to               50               amps               and               then               swings               back               to               12               amps               of               consumption.

I               got               sustained               40               to               45               amp               readings               while               I               pushed               the               mower               through               thick               grass               in               the               yard.
               After               mowing               the               yard               once               with               the               ammeter               installed,               I               quickly               realized               that               I               was               pulling               more               than               50               amps               of               power               once               the               batteries               started               running               down.

The               control               handle               of               the               mower               gave               out               a               month               ago               and               I               can               now               see               why               this               happened.

Reduced               voltage               from               the               batteries               lead               to               increased               amperage               pull               from               the               motor               which               drives               the               switch               circuitry               far               beyond               what               the               factory               electronics               can               deliver.

The               increased               amperage               drain               also               heated               up               the               electronics               in               the               control               handle               of               the               mower               which               degraded               its               ability               to               perform               reliably               the               next               time               I               mowed               my               lawn.
               Summary;               Conclusions               Drawn               From               Three               Years               Of               Using               The               CMM1200
               So               far               my               most               frustrating               problem               with               the               cordless               mower               is               that               I               was               not               able               to               get               my               batteries               charged               with               enough               power               because               of               the               failing               circuitry               in               the               handle.

As               the               switches               in               the               handle               lost               their               ability               to               make               solid               contact,               the               batteries               no               longer               got               a               solid               charge               and               the               motor               itself               could               not               get               enough               power               to               cut               grass.

Ever               since               I               replaced               the               jumble               of               wires               with               a               single               40               amp,               double               pole,               switch               the               mower               has               been               able               chew               through               the               grass               in               my               yard               with               ease.

All               thanks               to               what               I               learned               from               installing               this               ammeter.
               I               never               knew               that               I               was               pulling               50               amps               of               24VDC               power               with               this               cordless               electric               lawn               mower               while               working               in               the               yard.

All               of               my               work               shows               that               we               still               have               a               long               way               to               go               before               gasoline               engines               can               be               cleanly               replaced               with               electric               motors.

Still               today,               we               do               have               options               and               I               intend               on               getting               the               most               out               of               these               green               machines,               one               step               at               a               time.
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