Dual rotor axial flux motor design

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Miles   100 GW

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Re: Dual rotor axial flux motor design

Post by Miles » Apr 04 2012 3:37am

Miles wrote: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 :D

Reasonable compromise?
I kept the endturn for the sake of uniformity :)

It makes for a neat connection.
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Miles   100 GW

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Re: Dual rotor axial flux motor design

Post by Miles » Apr 04 2012 5:28am

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)

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Miles   100 GW

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Re: Dual rotor axial flux motor design

Post by Miles » Apr 04 2012 6:33am

Above data in Drive Calc:
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Re: Dual rotor axial flux motor design

Post by Miles » Apr 06 2012 12:00pm

Finished designing the stator (for now...)
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Miles   100 GW

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Re: Dual rotor axial flux motor design

Post by Miles » Apr 08 2012 4:30am

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...
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fechter   100 GW

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Re: Dual rotor axial flux motor design

Post by fechter » Apr 08 2012 10:40am

8X less loss at the current limit would be nice. If you can come anywhere close to predicted it will be great.
"One test is worth a thousand opinions"

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Miles   100 GW

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Re: Dual rotor axial flux motor design

Post by Miles » Apr 09 2012 3:25pm

Just because I like rendering... :)
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TylerDurden   100 GW

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Re: Dual rotor axial flux motor design

Post by TylerDurden » Apr 09 2012 6:45pm

Bling! :mrgreen:
Have a Nice Day,

TD

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Re: Dual rotor axial flux motor design

Post by Miles » Apr 10 2012 6:27am

TylerDurden wrote:Bling! :mrgreen:
:)
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fechter   100 GW

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Re: Dual rotor axial flux motor design

Post by fechter » Apr 10 2012 8:21am

Solid gold windings should have less resistance than copper. :wink:
"One test is worth a thousand opinions"

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Re: Dual rotor axial flux motor design

Post by Miles » Apr 10 2012 8:41am

fechter wrote:Solid gold windings should have less resistance than copper. :wink:
You'd think so but apparently not, which is why they are gold plated silver :wink:

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

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Re: Dual rotor axial flux motor design

Post by TylerDurden » Apr 10 2012 8:57am

And the stator lams?
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Re: Dual rotor axial flux motor design

Post by Miles » Apr 10 2012 9:04am

TylerDurden wrote:And the stator lams?
Platinum plated Cobalt alloy :P

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Re: Dual rotor axial flux motor design

Post by Arlo1 » Apr 10 2012 9:36am

Miles wrote:
fechter wrote:Solid gold windings should have less resistance than copper. :wink:
You'd think so but apparently not, which is why they are gold plated silver :wink:

Ref: http://www.thecarpcstore.com/cms/index. ... &Itemid=68
Sounds like a cheep build so lets get to production.
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Re: Dual rotor axial flux motor design

Post by Kingfish » Apr 10 2012 11:58am

Plating: I believe that to assuage intermetalics between layers that it needs to be Copper-Nickel-Gold. 8)

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Re: Dual rotor axial flux motor design

Post by TylerDurden » Apr 11 2012 1:49am

Miles wrote:
TylerDurden wrote:And the stator lams?
Platinum plated Cobalt alloy :P
But of course... pure platinum is too heavy!!
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Re: Dual rotor axial flux motor design

Post by Philistine » Apr 11 2012 1:55am

Did P Diddy get a DUI?

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Miles   100 GW

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Re: Dual rotor axial flux motor design

Post by Miles » Apr 11 2012 2:15am

Philistine wrote:Did P Diddy get a DUI?
No. He's upgrading the motors on his Segway.....

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fechter   100 GW

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Re: Dual rotor axial flux motor design

Post by fechter » Apr 11 2012 8:10am

Miles wrote:
fechter wrote:Solid gold windings should have less resistance than copper. :wink:
You'd think so but apparently not, which is why they are gold plated silver :wink:
I stand corrected :oops:
We'll just have to wait until we can get graphene sheets.
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Re: Dual rotor axial flux motor design

Post by Arlo1 » Apr 11 2012 8:21am

fechter wrote:
Miles wrote:
fechter wrote:Solid gold windings should have less resistance than copper. :wink:
You'd think so but apparently not, which is why they are gold plated silver :wink:
I stand corrected :oops:
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.
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Re: Dual rotor axial flux motor design

Post by hal2000 » Sep 30 2013 2:48pm

I followed this thread to this point but it seems that you have abandoned this design in favor of a radial design. Could you give a brief summery of why you decided to switch designs..

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Miles   100 GW

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Re: Dual rotor axial flux motor design

Post by Miles » Sep 30 2013 2:57pm

Hi Hal,

I wanted to get some experience with a more conventional motor before I tackled this.... I'm still thinking about this one, though....

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Re: Dual rotor axial flux motor design

Post by Miles » Feb 10 2014 3:51am

I've started re-working this design. Diameter increased to 126mm and it's now configured for 24t 22p. I'll turn the coils inside out so, the crossover and inter-connections will now be on the outside.....
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Miles   100 GW

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Re: Dual rotor axial flux motor design

Post by Miles » Feb 10 2014 6:23am

Open slot version
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Re: Dual rotor axial flux motor design

Post by h0tr0d » Feb 10 2014 9:07am

How do we hold those parts to form a 1 piece stator and how do we cool that?
Thank you Justin! Life is so much sweeter with this forum... ;)

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