Search found 213 matches

by coleasterling
Oct 16 2019 8:41pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

I use very few keyboard shortcuts and do far more gestures. I think you should just dive in. You can worry about assigning shortcuts later. Start with basic shapes. Draw a 2d rectangle and extrude (push-pull) it to a cube. Draw a circle and extrude it to a cylinder. Draw a shape and revolve it to a ...
by coleasterling
Oct 15 2019 1:09pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

I think it is mostly a waste of time to try to create any sort of finished hand sketch if you know you're going to make a solid model. Napkin sketch it, then start making geometry in CAD. I really think you'll pick it up quickly enough to save significant time.
by coleasterling
Oct 14 2019 5:05pm
Forum: Motor Technology
Topic: Serious FOCer (84V VESC 6 based controller)
Replies: 174
Views: 9981

Re: Serious FOCer (84V VESC 6 based controller)

I was reading along and looking at pictures and thought, "Dang, that end board looks sketchy." Great thought, but I agree, probably better to move away from it unless you could make some sort of bracket to screw it to the other board.
by coleasterling
Oct 14 2019 2:52pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

As long as the program can export the model as an STL file, pretty much any slicer will make code from it. STL is a horrible format and I'm not sure why it became the go to format for 3D printing. Fusion will export .stl files and I believe even has plugins for slicing in the software. The real powe...
by coleasterling
Oct 12 2019 7:34pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

Well darn, makes sense when you say it.

So maybe instead of steel, use the fiberglass we've been talking about as the face sheets?
by coleasterling
Oct 12 2019 2:56pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

Sorry, just a sandwich panel using the smc as the core and a set of traditional lamps as the face sheets.

https://en.m.wikipedia.org/wiki/Sandwich_panel
by coleasterling
Oct 12 2019 1:36pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

I have an idea for this, but it would require some testing. What about a single traditional lamination on either side of the powdered core? Say 0.2-0.3mm, laser-cut. Machine the powdered iron into whatever shape we need to be able to use the surplus material(probably the same trapezoids we're using)...
by coleasterling
Oct 11 2019 3:43pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

Nothing to add to the last few posts other than that a more round geometry is easy to do and probably better for stress concentrations on the cores. External sharp corners are generally bad just like internal sharp corners. The threading test worked well, but I found another issue in that on tighten...
by coleasterling
Oct 10 2019 5:25pm
Forum: Motor Technology
Topic: Serious FOCer (84V VESC 6 based controller)
Replies: 174
Views: 9981

Re: Serious FOCer (84V VESC 6 based controller)

Excited to see how it turns out!
by coleasterling
Oct 07 2019 11:22am
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

The axle is made out of 2" aluminum stock, with less wasted material. The adapter ring thats bolted to that, is 1/2" flat stock, cheap and easy, with lots of holes drilled into it, for air and wires. The core support ring is 1/4" aluminum, or 1/8" steel, and is pretty straight forward. If you use t...
by coleasterling
Oct 07 2019 11:18am
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

if you don't mind, i would suggest you to make smc core shape simplier. like this one (height is 35 mm): SMC core #2.jpg making core like this will save you expensive smc material and labor for cnc machining. please also look at the axial flux stator fechter showed us few times: Cores with no overh...
by coleasterling
Oct 07 2019 11:14am
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

The support ring for the cores should go all the way to the outer edge for the most support. If the support ring was fairly thick aluminum, it could be used to carry heat away from the cores if it was attached to the housing. Water cooling could even be done by having channels or tubes on the suppo...
by coleasterling
Oct 07 2019 11:02am
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

Am I making things up, or should the slot gap be about the same width as the magnet thickness? I feel like I've read that a few places.

Responses to specific posts upcoming:
by coleasterling
Oct 04 2019 7:14pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

I'll respond to the last several posts later, but I think the cores can reasonably be tapped and screwed from behind. I'll do a test and see what kind of force a 10-32 thread can take in the #40 before failure. In general, it is actually a little less brittle than I expected. I don't think there wil...
by coleasterling
Oct 04 2019 11:40am
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

Do we need to care about how well the segments mate and touch to complete the path? Like will the edge contact matter much? I could make the segments overlap, though that'd add some time and cost. The sample I made is set up as an 18/16 count already. Does the dual stator design we're discussing typ...
by coleasterling
Oct 03 2019 3:02pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

Got the first one made. Keep in mind this thing is pretty small, barely larger than the footprint of a penny. The top and bottom overhanging faces are 0.065" and 0.080" thick, respectively. The thickness is ~0.75". There's significant breakout on the edges of the bottom, primarily due to my chosen w...
by coleasterling
Oct 02 2019 5:03pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

Well, after all that talk, I had a customer come in and I wasn't able to do any real machining today. I did lop one side off and it isn't bad. Just turns to powder like other SMC's.
by coleasterling
Oct 02 2019 3:30pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

Here we go:
by coleasterling
Oct 02 2019 2:46pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

So that render is a section of a full circle, sized so that the pieces would all touch when assembled. I didn't put realistic measurements to it, but I assumed you could fit them together like that and still have enough space for winding. Gimme a minute and I'll get a better render up of a full mode...
by coleasterling
Oct 02 2019 11:27am
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

On that same note, if y'all can get me some general dimensions, I can make something that might actually be usable vs. just throwing some stuff out there randomly. Material won't be here until 3 or so.
by coleasterling
Oct 02 2019 11:26am
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

So you want some...back iron?...integrated into the cores? That's doable, but of course not with the surplus material. I assume we don't want holes because that's a high-flux area? What if the cores were made with a "T" shape where the standing leg of the T were bolted into a silicon steel plate? Wo...
by coleasterling
Oct 01 2019 10:47pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

APL wrote:
Oct 01 2019 8:58pm
Geez coleasterling, you must be reading my mind, that looks perfect! Do yo have CNC?
I own and run a full CNC prototyping shop in Texas. We have a 50 taper VMC, 4-axis 40 taper VMC, and a 3-axis turning center with live tooling.
by coleasterling
Oct 01 2019 4:07pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

Y'all want to see something like this? I should get my stuff tomorrow and can knock one out.
by coleasterling
Sep 27 2019 12:15pm
Forum: Motor Technology
Topic: APL's DIY axial-flux motor
Replies: 717
Views: 32915

Re: APL's DIY axial-flux motor

I just purchased two of the #40 blocks (guy is in Texas!) and will try machining on them. He also has over 200 pieces left. The supply probably won't go away anytime soon unless he sells the lot. They are cheap enough to buy many to keep on hand, though.