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by APL
Mar 29 2020 1:03pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

From time to time I see a motor, with a stator tooth that has a groove down the center of it, and wondered what it was for. After looking around, I found that sometimes grooves were used to get the motor to move in one direction more than another by placing a groove towards one side of the tooth. Bu...
by APL
Mar 27 2020 1:31pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

Can't break the laws of physics I guess, and there aren't any materials strong enough that are not conductive, except for glass, and ceramics. Plus the idea of a flux gap carrier is just added inefficiency to an already slightly compromised SMC core, so I guess I'll shelve the idea, and concentrate ...
by APL
Mar 25 2020 8:37pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

Thinking about it incrementally, The small section between the stator cores 'A', is obviously OK, but the large section in 'B' is questionable, and the circular piece 'C' is definitely a one turn short. The last one 'D', is also in question. Back iron short..png After doing some experimenting today,...
by APL
Mar 24 2020 2:11pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

I'm probably going down a dead end street, but I'm trying to understand what the deal is. Laminated, or SMC ring. I thought about that, and I figured that it would be needed for eddy current-hysteresis losses during pole switching. But that the one turn short might be a different effect, and occurs ...
by APL
Mar 23 2020 12:58pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

A few pages back I was asked if I was planing to use a steel ring for the stator core carrier, and I replied that it would cause a 'one turn' short around the cores, much like the aluminum carriers in the last motor build did. That is, it would act like a large single turn of wire, around the core, ...
by APL
Mar 20 2020 1:33pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

Really! Thats awesome. I was wondering if you might have better sources, as a machine shop. The point is a bit mute though, if you say it machines about the same, too bad, I was hoping it was stronger. This stuff machines like packed dirt. Still, good to know that at least it may be possible to try ...
by APL
Mar 19 2020 8:16pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

Found some info on the production process, a little outdated (2016), but it shows the basics. Theres a heat treatment and cure step that helps bond it and achieve the desired specs. 1hr at about 300 C. SMC mfg process .jpg Taken from "Magnetics"; https://magneticsmag.com/insulated-iron-powders-smc-c...
by APL
Mar 17 2020 1:31pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

I've also been revisiting the idea of pressing your own cores DIY style. It occurred to me that the atomize-coated iron powder that SMC is pressed from might be purchased and pressed into a machined steel mold, using a hydraulic jack and a shop press. Easier said than done, but still might be possib...
by APL
Mar 15 2020 1:13pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

Then theres the use of magnetic slot wedges, for open slots. Slot wedges have been in use in radial motors for a long time as a means to keep windings in both stationary, and rotating masses. And are usually found in high slot count machines. Usually made out of long, non magnetic polymer strips, th...
by APL
Mar 14 2020 1:31pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

Thats good to know, I didn't see it in my searches. The question is still how much, and as usual, a test will probably be in order, as every situation is different. I might be able to do that test on this motor later on though, if it isn't too hard to do. (it's my obsession with weight) :wink: In my...
by APL
Mar 12 2020 8:54pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

In assessing the core weight, I'm looking closer at the tooth tip, sometimes called brim, or lip, and overhang. On the present design core, it accounts for a large percentage of the weight. It's not just the tip, but the whole face area that is as thick as the tip profile. On this core, a 4mm thick ...
by APL
Mar 09 2020 1:18pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

Needed to take some time out to get some core material ready for machining, so that once the bonding, anodizing, and a few other loose ends are done, they will be nearing completion. Once the original block of SMC was marked out, I got a little shock, realizing that it was going to take the entire 2...
by APL
Mar 05 2020 1:32pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

Fechter, Your idea of using a big magnet on the other side for bonding is a good one, but it got me thinking. Instead of using thick back iron on a motor, it might be plausible to use magnets in between the PM's on the back side. Between the split in the flux pattern. There seems to be a nice square...
by APL
Mar 04 2020 9:01pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

Well, actually, I am. I'm just getting started. I don't plan to do every build on here, but I'll show them off. It's called, "having a hobby". And every hobby has it's specialized tools. Many times you have to make them. I like the idea of making my own cutter. It solves the trapezoid magnet problem...
by APL
Mar 04 2020 2:00pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

Finally finished the rotor PM's, theres a few that need replacing, but there it is. Now it's on to the dreaded bonding process. At least it 'looks' like it has a chance of hauling my butt down the road. :) V2 PM's finished..jpg We shall see, if not, I can always make new ones. It is possible to put ...
by APL
Mar 04 2020 1:46pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

Interesting to see all the different types, I wasn't aware of the ram type. The continuous wire saw is interesting, and would probably make a good cutter. It's unclear as to whether the wire is re-used or just consumed. It's also interesting to see that very small holes can be drilled in super hard ...
by APL
Mar 03 2020 3:01pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

Thanks Ribiero, where theres a will, theres a way,.. hopefully it will work, but won't know until we try. :thumb: EDM is another idea that might work, your right fechter, I've been holding off on the idea, because I don't really understand it yet, and it seems a little more complicated. It does have...
by APL
Mar 02 2020 9:08pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

Yes, I fear that just the scoring with the Dremel disc is heating them up too much. They still have good power, but not as much as original. I'll keep going, and see what happens. I have been thinking more and more about building a cutting machine. Not right away,.. but later this summer maybe. It w...
by APL
Mar 02 2020 2:17pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

Found this chart for magnet properties, and can be found under many E-bay add's. I don't remember seeing it before, but it shows the temperature range and typical T-strength of the Neo-magnet materials. Of course, N52 is the worst, as far as temperature goes. Just my luck. But it's interesting to se...
by APL
Mar 01 2020 2:51pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

Also, theres the possibility of making a DIY water jet machine, or at least, a straight line cutter with a screw drive. Maybe convert some old 3D printer parts. Would be slow, but it would work. I know, you can tell,.. I'm a DIY guy. :lol: Anyway, could be useful for cutting out other things as well...
by APL
Feb 29 2020 2:20pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

I found this video of a magnet being water jet cut, and it looks feasible,.. of course some before and after magnetic test would have to be done. The video is of two guys horsing around, so if you don't want to wade through it, just go to 4:36 and again at 7:07. Obviously, some preparation/mounting ...
by APL
Feb 28 2020 9:26pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

Thats good to know. I looked up neodymium magnetizing on Youtube, and found some videos of the process. I suppose a person could make a machine, but I wouldn't want to,.. those things are rude! https://www.youtube.com/watch?v=h7_z93Xklmo But,.. there must be places that offer the service. Depending ...
by APL
Feb 28 2020 2:37pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

Here's a picture of a big windmill generator, in the process of getting some magnets bonded,.. talk about pinched fingers! :shock:
Jumbo Magnets.jpg
Jumbo Magnets.jpg (28.15 KiB) Viewed 889 times
by APL
Feb 28 2020 2:30pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

After looking at this chart of the magnet manufacturing process, I can see that the magnets are machined at the end, and the last thing that is done, is the magnetizing. This begs the question as to wether a magnet can be re-magnetised. I don't know what the machine for magnetizing is like, probably...
by APL
Feb 28 2020 2:21pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 1013
Views: 86071

Re: APL's DIY axial-flux motor

A powerful collection of links! :thumb:

Your parametric design tool is a great idea, and saves many hours of effort. Coupled with the Bavaria link for winding
schemes, one can visualize a viable axial motor concept in minutes. http://bavaria-direct.co.za/scheme/calculator/
Excellent work!