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  1. HalbachHero

    DIY Toroidal Axial Flux PM

    I have spent some time recently making some improvements to the potting press that I had used in previous iterations. I made it so that I can use machine screws to close the press tightly, which should make it much easier to fit it in the vacuum chamber, and the pressure should be a bit more...
  2. HalbachHero

    DIY Toroidal Axial Flux PM

    Thanks for that suggestion. I definitely got a cheaper quote from CNC Madness than I did from Send Cut Send. Also, they mentioned that they have 0.2mm carbon fiber too after reaching out to them. I think this design will work well. It's still solid enough to wind around. The holes should...
  3. HalbachHero

    DIY Toroidal Axial Flux PM

    I would imagine it might be conductive, but insulated from the enabled magnet wire. I am not sure it it would impact the performance or not. It's a good question. Thanks for the pointers. I made some changes to the design again and added voids per your suggestions. The voids correspond nicely...
  4. HalbachHero

    DIY Toroidal Axial Flux PM

    After a few more iterations. I landed on something I think I like. This is 3 phases, with 5 turns each and It's just a little under 2mm thick. I only added the "gear teeth" between each phase instead of each turn, and was able to get them to pile up next to each other nicely. Obviously I need to...
  5. HalbachHero

    DIY Toroidal Axial Flux PM

    The last attempt at the Faulhaber winding was just a test. After tweaking things a few times, I managed to make this. This is two 3d printed pieces that I glued together. There are three turns on each phase, still 12 poles. I decided to give up on the stranded wire. I switched to a 24 AWG...
  6. HalbachHero

    DIY Toroidal Axial Flux PM

    Lately I have been helping another maker with some simulations and found some information that might be obvious. But ideally the halbach array is tightly packed (minimize the gaps between poles, but also that the halbach magnets are the same width and height as the axial ones. Heres the data...
  7. HalbachHero

    DIY Toroidal Axial Flux PM

    In paralell to testing the one working motor, I have been working on the next version. Even though I had already made a set of rotors that has yet to be used (due to not being able to get the center piece machined). I found that there was actually quite a bit of space between the inner...
  8. HalbachHero

    DIY Toroidal Axial Flux PM

    Thanks, I have been using the "calc apply old" for my manually entered values. I believe that I had incorrectly calculated my resistance values, but to no avail. I have been playing with HFI, also with no luck yet. Admittedly all the settings are a bit beyond me, I am slowly trying to learn...
  9. HalbachHero

    DIY Toroidal Axial Flux PM

    Yes, but the numbers that appear are pretty wacky when I do that. I have to imagine it has something to do with the bad resistance reading, but I'm not positive. I have had the most success using calculated values and adjusting
  10. HalbachHero

    DIY Toroidal Axial Flux PM

    So I have purchased a VESC (finally). Its the VESC 6 EDU from Trampa boards. I got the VESC tool as well, and have started to wrap my head around it. I think I have a decent understanding of the basic FOC settings, but I am unable to get it to start sensorless. I have measured the Kv (Spun...
  11. HalbachHero

    DIY Toroidal Axial Flux PM

    So would this be a power equation? I used 12, which was voltage. But if it's power, would it be power from the power supply? Or something other value? If it's from the power supply it's 12vx4A=48w P=I^R Then 48w=I^2 * 0.3117 I = ~12A Am I missing something?
  12. HalbachHero

    DIY Toroidal Axial Flux PM

    Thanks for the input :)
  13. HalbachHero

    DIY Toroidal Axial Flux PM

    Thanks for the feedback. Phase to phase resistance is not something I have been able to measure accurately. But based on the parameters of the conductor. I have calculated it at 0.31177 Ohms. I'm not sure how to get current from that, but I would assume its just V= I * R 12 = I * 0.31177 I...
  14. HalbachHero

    DIY Toroidal Axial Flux PM

    Soooo I still have yet to fix the pressure pot. But I was able to make some progress in others ways. A while back someone reached out to me after my last YouTube video. They ended up making a part for me but due to the 3D printer optimized design, it was not right when it was made out of...
  15. HalbachHero

    DIY Toroidal Axial Flux PM

    While winding it went great, tying it down was a huge pain. The find that had pulled in close together made it very difficult to get the thread where it needed to be and it was all so tight that it kept breaking the kevlar thread. I could potentially get thicker thread, but I think the real...
  16. HalbachHero

    DIY Toroidal Axial Flux PM

    Thanks! Finished winding the next stator, but I still need to tie it down. The machine definitely helped, but working with the copper was different from the string and I had expected. having everything stay tighter, and in once place while I wound it was a huge advantage. I think it only took...
  17. HalbachHero

    DIY Toroidal Axial Flux PM

    I finished the new nylon winding using the new winding machine contraption, I also tied it down with the kevlar. This time I tied it down twice at each overlap hopping to keep the shape of everything better as I tightened it up. I think it came out much better. and I am curious how this will...
  18. HalbachHero

    DIY Toroidal Axial Flux PM

    I actually forgot I had a spreadsheet where I calculated it given the phase length and the properties of the wire So if that's accurate, ~0.156 Ohm
  19. HalbachHero

    DIY Toroidal Axial Flux PM

    Hey all, its been a while. The spring and summer were warm, and I needed to get out of my basement for a bit. Spent some time growing a garden and enjoyed life. But I have recently returned to the basement... To answer some recent messages. I found that this was actually quite broken...
  20. HalbachHero

    DIY Toroidal Axial Flux PM

    Sorry to let you down, but I only use Fusion 360, I tend to use the dark mode with many applications, that's why it might look different
  21. HalbachHero

    DIY Toroidal Axial Flux PM

    Have I mentioned how much I regret choosing this username.... Thanks! This is the first project I have ever really tried to 3D model, and I have learned a lot over time. I feel like I can really use it as a tool now and it's certainly useful to show how everything is assembled. Ti is a good...
  22. HalbachHero

    DIY Toroidal Axial Flux PM

    The aluminum was really just to fill the void in the center, but needed to be structural for any axial loads. I made the steel a minimal as possible because I had initially dreamed on it not having a center and becoming a donut. But I realized I care more about spinning it faster which means...
  23. HalbachHero

    DIY Toroidal Axial Flux PM

    Also, happy cake day to this thread. I just realized I started posting a year ago today. Its been quite a journey, I'm excited to see where it goes in the next year(s)
  24. HalbachHero

    DIY Toroidal Axial Flux PM

    Here's another image of the new back iron with the new hub that I am thinking. This reduces the amount of material that needs to be machined, and allows the laser cut steel to act as the main structural piece inside magnet ring. I might tweak the aluminum part some more so its even easier to...
  25. HalbachHero

    DIY Toroidal Axial Flux PM

    back from more radio silence. I had gone on vacation, so I've been quiet lately, but my mind has been all over the place lately with what I want to do next. So I decided pretty much immediately that I don't like these rotors. because I think the amount of aluminum you can fit (at most the...
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