Dual rotor axial flux motor design

Miles · Apr 4, 2012

Miles said:
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 · Apr 4, 2012

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 · Apr 4, 2012

Above data in Drive Calc:

Miles · Apr 6, 2012

Finished designing the stator (for now...)

Miles · Apr 8, 2012

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 · Apr 8, 2012

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

Miles · Apr 9, 2012

Just because I like rendering...

TylerDurden · Apr 9, 2012

Bling!

Miles · Apr 10, 2012

TylerDurden said:
Bling!

fechter · Apr 10, 2012

Solid gold windings should have less resistance than copper. :wink:

Miles · Apr 10, 2012

fechter said:
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.php?option=com_content&view=article&id=51&Itemid=68

TylerDurden · Apr 10, 2012

And the stator lams?

Miles · Apr 10, 2012

TylerDurden said:
And the stator lams?

Platinum plated Cobalt alloy

Arlo1 · Apr 10, 2012

Miles said:
fechter said:

Solid gold windings should have less resistance than copper. :wink:

Click to expand...

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

Ref: http://www.thecarpcstore.com/cms/index.php?option=com_content&view=article&id=51&Itemid=68

Sounds like a cheep build so lets get to production.

Kingfish · Apr 10, 2012

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

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

TylerDurden · Apr 10, 2012

Miles said:
TylerDurden said:

And the stator lams?

Click to expand...

Platinum plated Cobalt alloy

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

Philistine · Apr 10, 2012

Did P Diddy get a DUI?

Miles · Apr 11, 2012

Philistine said:
Did P Diddy get a DUI?

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

fechter · Apr 11, 2012

Miles said:
fechter said:

Solid gold windings should have less resistance than copper. :wink:

Click to expand...

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.

Arlo1 · Apr 11, 2012

fechter said:
Miles said:

fechter said:

Solid gold windings should have less resistance than copper. :wink:

Click to expand...

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

Click to expand...

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.

hal2000 · Sep 30, 2013

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..

Miles · Sep 30, 2013

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....

Miles · Feb 10, 2014

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.....

Miles · Feb 10, 2014

Open slot version

h0tr0d · Feb 10, 2014

How do we hold those parts to form a 1 piece stator and how do we cool that?

Dual rotor axial flux motor design

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