I've looked at pretty much copying the methods use by Charles for the external sensors, the problem is that you still have to tune the sensor to the motor, and this will change every time you pull the assembly apart. My currently idea is to try to develop a PCB that will fit inside the motor near the mount and stator to position the hall sensors between the stator teeth. This will remove the need to tune them in and will still provide enough cooling to avoid heat damage (A few industrial brushless motors I have seen have the hall sensors epoxied between the stator teeth)




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