Miles wrote:How about the following idea for connecting up the coils?
- Before assembly, crimp the ends of each coil strip around a gold-plated tube (bullet connector?).
- Use gold-plated copper wire to form the bridging links.
- Wire is a push fit into the ID of the tube (end could be tapered).
fechter wrote:On your rotors, it might be good if there was a small lip on the OD to help keep the magnets from flinging off at high speeds. I don't trust glue that much. Also, if the rotor hub was mild steel, it could help the back iron or replace the back iron.
Why would it be better?fechter wrote:I guess you're suggesting making the cores longer to fill the space. It would be better to move the rotors inward to shorten the gap.
Miles wrote:fechter wrote:On your rotors, it might be good if there was a small lip on the OD to help keep the magnets from flinging off at high speeds. I don't trust glue that much. Also, if the rotor hub was mild steel, it could help the back iron or replace the back iron.
Yes, I'm intending to put a lip on, possibly by milling shallow pockets for each magnet, which would also give the spacing.
I haven't modelled that part here, yet. It's something that came out of Thud's epic "MULE" thread: viewtopic.php?p=214408#p214408Kingfish wrote:On the connections between coils, it is apparent how the outer layers are wired though not obvious how the inner are connected with the flatness of the inside end-turns: How is this accomplished?
The original plan was to have a centrifugal fan doubling as the brace separating the two rotors. Now, I'm not sure that will be necessary....? It would be a continuous addition to the parasitic losses. The passive cooling from air flowing through the stator, around the large areas of exposed copper, should be pretty effective.Kingfish wrote:What is your plan for active cooling?
Yes. In fact I've just been contemplating this very point, as I'm starting to model it There will be an asymmetry, but there will still be the same number of conductors on each side, in total. Right? As the force acts from the core and not the coil, I assumed the asymmetry wouldn't be a problem.Kingfish wrote:The only issue I can foresee is that one side of the coil will have more pull due to the double-back unless the begin & end terminations are on opposite sides of the coil – so that you have the same count of conductors on each side. Make sense?
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