Endless Sphere

With more of these cars ending at the scrap yard every year it might be profitable for someone to design a CNC made motor casing and axle for these motors. And to find a suitable controller to drive it. That's exactly what I had originally planned to do. The motor is large enough that machining the...

Years ago, there were some guys that reported using them at around 60kW burst in a racing application. They never provided details and disappeared. I worked on a housing for awhile before moving to some other hybrid motors. I'll finish the IMA project at some point, but it is low on the list.

Though not *technically* suitable, I run fusion on my at-machine computer just fine, which is an older Thinkpad t420 with an i7 and 10gb (unbalanced) memory. I use t420's at my machines because they are stupid cheap on ebay and I know they'll get trashed with all the metal dust in the air. The last...

Though not *technically* suitable, I run fusion on my at-machine computer just fine, which is an older Thinkpad t420 with an i7 and 10gb (unbalanced) memory. I use t420's at my machines because they are stupid cheap on ebay and I know they'll get trashed with all the metal dust in the air. The last ...

https://www.autodesk.com/campaigns/fusi ... -hobbyists

Make an account and I believe you'll get a hobbyist license key at some point. It is definitely 100% free, not just a 30 day trial, though I know it says 30 days upon install.

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 ...

Yep, I like it.

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.

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.

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...

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?

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

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)...

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...

Excited to see how it turns out!

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...

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...

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...

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:

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...

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...

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...

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.

Here we go:

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...