Dual rotor axial flux motor design

[Miles]

Accepting some imbalance, I'm leaning towards increasing the number of turns from 4 to 6 and missing out the first half turn from the first module of each phase. Might as well gain the advantage of losing an endturn, too

Reasonable compromise?

I kept the endturn for the sake of uniformity

It makes for a neat connection.

[Miles]

Data for the 6t wind:

Kv 100 rpm/V (estimated)
Kt 0.0955 Nm/A (estimated)
Rm 8.8 milliohms (calculated)
Nominal speed 4000 rpm
Flux frequency at nominal speed 533 Hz
Core volume 8.5222E4 cubic mm (calculated)
Core mass 0.672 kg (calculated)
Voltage @ nominal speed 40V
Total parasitic losses @ nominal speed (Arnolds thin gauge GO 0.15mm @ 1.5T) 40 Watts (estimated)
No load amps @ 40V 1amp (estimated)

[Miles]

Above data in Drive Calc:

[Miles]

Finished designing the stator (for now...)

[Miles]

Comparison with Astro 3220 7t which weighs the same as my 'motor' and has the same torque constant. Not fair to compare theoretical against empirical but interesting nevertheless...

[fechter]

8X less loss at the current limit would be nice. If you can come anywhere close to predicted it will be great.

[Miles]

Just because I like rendering...

[TylerDurden]

Bling!

[Miles]

Bling!

[fechter]

Solid gold windings should have less resistance than copper.

[Miles]

Solid gold windings should have less resistance than copper.

You'd think so but apparently not, which is why they are gold plated silver

Ref: http://www.thecarpcstore.com/cms/index. ... &Itemid=68

[TylerDurden]

And the stator lams?

[Miles]

And the stator lams?

Platinum plated Cobalt alloy

[Arlo1]

Solid gold windings should have less resistance than copper.

You'd think so but apparently not, which is why they are gold plated silver

Ref: http://www.thecarpcstore.com/cms/index. ... &Itemid=68

Sounds like a cheep build so lets get to production.

[Kingfish]

Plating: I believe that to assuage intermetalics between layers that it needs to be Copper-Nickel-Gold.

Quick, place it under glass so it won't get dirty...
A jewel to behold in any Keep! KF

[TylerDurden]

And the stator lams?

Platinum plated Cobalt alloy

But of course... pure platinum is too heavy!!

[Philistine]

Did P Diddy get a DUI?

[Miles]

Did P Diddy get a DUI?

No. He's upgrading the motors on his Segway.....

[fechter]

Solid gold windings should have less resistance than copper.

You'd think so but apparently not, which is why they are gold plated silver

I stand corrected
We'll just have to wait until we can get graphene sheets.

[Arlo1]

Solid gold windings should have less resistance than copper.

You'd think so but apparently not, which is why they are gold plated silver

I stand corrected
We'll just have to wait until we can get graphene sheets.

I have a feeling it will be sprayed on or polished on. I have graphite sheets for conducting heat and power out of my fets... All you need to do is coat something with a smothe thin layer of it then coat it with somehting to stop it from rubbing off.