I'm using the smallest of Victors Siemens AC drive, the 92 lb,18KW 5105WS12, for my Insight conversion. It has a female DIN 5482 involute spline with 12 teeth. See http://www.omnigearandmachine.com/DIN5482-involute_splines.htm for details on this spline.
Since I'm omitting the clutch (yes, I have deviated from Wayland's dream a bit, and plan to eventually fix it in 2nd gear, since >100 mph is already too fast for my modest street use), the coupler will have a female spline to mate with the Honda transmission on the other end. The downside is that a coupler to the clutch plate would be more universal for subsequent conversions which upgrade the clutch, rather than restricted to the Honda transmission. Today I took the motor and transmission, as well as lots of data and drawings of the motor and coupler to American Machine and Gear, a local (Portland, Oregon) shop that seems to be recommended from a variety of sources. After considering the application, they suggested 4041 tempered steel (I didn't write it down immediately, so there may be some further attributes that I missed). I'll try to capture the exact material for documentation purposes when I pick it up next week. Was it the same motor that you used? It is helpful if we can develop a list of suppliers that have built particular parts, since it is much cheaper to build the second and subsequent part. Not to mention the benefit of following a well worn path of things that have worked for others. I know Victor is working hard to make this happen, too. Incidently, I used type 6061 T561 aluminum for the adaptor plate. It has worked well for Victor, but the machinist suggested that type 7075 would have been a more optimal choice. I was hoping to get some input from the list before starting, but, unfortunately, it was down. So I'll rely on their experience, but it would be nice to add this to the wealth of information that is this list. Gary > What spline do you need for the motor end? We had Webster Gears machine the > male splines for the Siemen's motors that we are using. If it is the same > spline, they might be a good place to have it made. > > Cliff ----- Original Message ----- From: "Gary Graunke" <[EMAIL PROTECTED]> To: <[EMAIL PROTECTED]> Sent: Wednesday, October 02, 2002 5:55 PM Subject: shaft coupler material > What material is best for a direct drive coupler? I'm having a coupler made > that connects an A/C driver motor (max RPM 10,000) to a Honda Insight > transmission shaft. The piece will be machined with male spline on the motor > end, and a female spine on the tranmission end. The max torque is 92 ft-lbs. > > Regards, > Gary >
