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by APL
Aug 03 2020 7:34pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

The new spacers are coming along. I need to spin them in the lathe yet, and carve out the insides for the wire clearance. I don't think it's going to push those around, they certainly look beefy enough, but it leaves little room for cooling. Such as it is, maybe I can machine some holes in them late...
by APL
Jul 31 2020 1:26pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

Good to know about the bearings,.. thanks. I never got to do any preload adjusting yet, theres to much trouble going on with the stator. But I'm definitely going to do that, along with tightening everything up that I can find that can be possibly loose. The aluminum stock for the spacers came today,...
by APL
Jul 29 2020 1:31pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

Thanks for the bearing info major, it's something that I hadn't really considered too much. I always figured that there was a magnetic balance. I probably am using the wrong type of bearings. Should be tapered roller bearings, since more of the force is showing up as axial. I'll have to look it up a...
by APL
Jul 28 2020 3:00pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

The stator plate is flat, and it is bending, unfortunately. But it doesn't appear to want to bend any further. The rotors are moving the rest of the way. I would think that there would be an equilibrium too, and I'm thinking it will be more so during operation, when the steel cores become opposing m...
by APL
Jul 27 2020 1:38pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

Yea, it's too bad, but to be expected actually. Same thing on the last motor. There's a lot of guesses work when designing things, and the strength of the magnets is hard to figure. I was never sure about the fiberglass either. Turns out that both the stator and the rotors are off by about the same ...
by APL
Jul 25 2020 1:09pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

The fiberglass is straight without the rotors. I spun the assembly on it's bearings. By laying it on it's side and putting two V-blocks under the bearings, it was less than .010" off anywhere side to side, using a dial indicator. When the motor is together, and I pry the fiberglass the opposite dire...
by APL
Jul 24 2020 9:53pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

Another idea is to make an adapter that fit's into a larger hole in the glass board, and bolts solidly down.
Axle addaptor..png
Axle addaptor..png (79.4 KiB) Viewed 520 times
by APL
Jul 24 2020 1:02pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

Darn dial up. I finally got a good shot of the motor from the side, and you can see that theres definitely something wrong in motortown. The stator appears tilted, but I also found out that the rotor assembly can be locked down in various positions as well, which can cause an illusion. Stator tilt.....
by APL
Jul 23 2020 2:50pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

Internet is out. Might be awhile.
by APL
Jul 22 2020 1:53pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

Another option, if need be, is to do it right and make the axle out of 4.5" round stock so that the axle flange is one piece. Wide axle flange..png I thought I needed room for wiring on that side before, and a piece of round stock that big is more expensive, but things are getting more serious now, ...
by APL
Jul 22 2020 1:16pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

I'm going to work on it today, and I'll take some pictures, but there might not be much that can be seen. I'll see how they turn out. The stator can be flexed by hand a 'little', and I'm going to try to pry the two sticking sides over the other way, and see if it snaps to the other side. If it does,...
by APL
Jul 21 2020 1:21pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

Bummer to be sure, but thats experimental, and inventing in general. Things don't necessarily show up until the end, and then when it rains, it pours. Par for the course, just one more problem to solve. The two rotors attraction is canceled out for the most part, I agree, but magnets and steel are a...
by APL
Jul 20 2020 8:43pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

Nope,.. not lucky. :( After three days of getting spanked, I think the culprit is a weak carrier. No matter how I space things, the magnets are always smack up against the cores the same way. So I'm getting that old feeling. I'm going to do a lateral strength test of the rotors and the stator separa...
by APL
Jul 19 2020 12:46pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

An aluminum center hub is not out of the picture yet, I think it could still be an option. I worry a little about the torque strength of the current set up, but we'll see what happens. If I have to rebuild the carrier, then so be it. The cores and wiring should come off in one piece, I just have to ...
by APL
Jul 18 2020 12:31pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

I was hoping for an easy assembly, but she's going to give me grief. Lots of little things, but the main snag is the air gap. I thought I had it dialed in, but there was still some bearing room between the rotors, so it's down to shimming and taking the motor apart several times. The pull power of a...
by APL
Jul 16 2020 1:24pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

Yea, she's a hefty girl,.. I'll find out what the final weight is today. I'm thinking I might have created a bigger motor than originally intended. :confused: The air gap is close to 1mm, but I haven't put it together yet with all the cores in, so I might have to adjust that a bit. Sensorless, yep. ...
by APL
Jul 15 2020 8:33pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

Yet another stator shot, I know,.. but this should be the last one. :wink: The wiring cleaned up quite a bit once the wires all found they're place's. I cut some small copper tubing with a tube cutter to make all the crimp & solder connectors, soldered in the phase wires, and she's all done! :thumb:...
by APL
Jul 09 2020 7:46pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

I finally got enough shop time to get the coils finished. Not an easy task,.. but done they are. Now it's time to face the rats nest of wires in the middle. But it will be joyful,.. because it's the last step before seeing it run. :thumb: V2 coils wound..jpg Bavaria winding diagram shows a pretty si...
by APL
Jul 02 2020 1:20pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

Thanks, thats good to know,..guess I won't worry too much. I've been thinking of putting a temp sensor in the wires, I might get more serious about that, just for the data if nothing else, and it would help to keep an eye on things. Since I'm using 200C enamel, (392F), evidently it can take an awful...
by APL
Jul 01 2020 12:45pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

It's my own fault Coleasterling, I should have known better. It's mostly the brim ends on the top and bottom. And I should have used tape from the start anyway. Didn't show up on the first coil I did, so I thought it was good to go, and I really thought that this 200C enamel was tough enough too. I ...
by APL
Jun 30 2020 8:53pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

Not much to show for all the time I've spent on it, but I had a few false starts. Found some shorts because of the brim edges, and had to go back and de-burr & rewind, and wrap some Kapton tape on all the cores. Once I got started, I was wishing that I had used the 15 awg wire instead. The 14 awg is...
by APL
Jun 25 2020 8:58pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

I see what you mean by the CSA major,.. so a shorter tooth is desirable. The minimum width or span to avoid saturation is related to the max current intended, or Tesla's developed. A 1K motor could be narrower than a 2K motor. I'm not sure how brim length ties in to that, but I've seen some really l...
by APL
Jun 24 2020 7:50pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

I've been busy with the drudgery of winding the coils on this motor. (remember the motor?) It's been slow going. I had to spend a lot of time finishing the core machining for the mounting screws and standoffs, so they could be mounted. I should have let Coleasterling do it when they were made, but I...
by APL
Jun 24 2020 1:37pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

I'm not sure about the math concerning lamination direction, I haven't looked too closely at it since it's generally understood to go in the direction of rotation. But then theres the Metglass wound cores, which beg to differ. So there may or may not be more to understand there. They do have a slit ...
by APL
Jun 23 2020 1:36pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1176
Views: 105006

Re: APL's DIY axial-flux motor

It brings me back to a question that has been nagging me for a while,.. seeing cores like this. I've always wondered, just
how important the 'center' of the core is to axial motor operation.