Farfle joins the MENS club

Electric Motors and Controllers
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Farfle   1 MW

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Re: Farfle joins the MENS club

Post by Farfle » Jul 17 2012 12:27pm

I sent this DXF to a few lam shops, and laser laminations in AR, can do it for 369 dollars, and may give me a small sponsorship, we will see.
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Miles   100 GW

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Re: Farfle joins the MENS club

Post by Miles » Jul 17 2012 12:50pm

Great! That sounds pretty reasonable. That's just the laser cutting?

If you need any advice on Alibre, feel free to ask - I've been using it for years.
Another possibility: http://www.deelip.com/?p=6517
SketchUp isn't really the right tool.....

What magnets did you use for your simulation?

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Farfle   1 MW

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Re: Farfle joins the MENS club

Post by Farfle » Jul 17 2012 4:35pm

Yeah, I like alibre alot, but all I have tried is the 2d modelling. I used n37 magnets out of the materials library on that sim
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Re: Farfle joins the MENS club

Post by Miles » Jul 17 2012 4:50pm

Farfle wrote:Yeah, I like alibre alot, but all I have tried is the 2d modelling.
Actually, the 2D modelling in Alibre isn't that great.... It's getting some attention at the moment, though.

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Farfle   1 MW

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Re: Farfle joins the MENS club

Post by Farfle » Jul 17 2012 8:38pm

Miles wrote:
Farfle wrote:Yeah, I like alibre alot, but all I have tried is the 2d modelling.
Actually, the 2D modelling in Alibre isn't that great.... It's getting some attention at the moment, though.

The other software that I use for 3d is sketchup, and for serious stuff, I have a copy of inventor that im somewhat good at. Inventor is VERY tedious tho.

heres some pics of the outside of the motor, and the stator support. Weight so far is 8 pounds:

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Farfle   1 MW

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Re: Farfle joins the MENS club

Post by Farfle » Jul 18 2012 11:51am

Found a little wheel speed /sprocket tooth count calculator online, at 3000 rpm it looks like looks like ill need about a 2.5:1 to 3:1 reduction for 60mph and quick acceleration at 20kw. So, whats the deal with tooth count, I don't really have a good feel for how much can handle how much. So if im running #35, would 20-60 be overkill? or can I get away with 16-48? I have used # 35 in FRC robotics, and have never broken one, but it does seem fairly small, and chews thru smaller alum sprockets quickly, so maybe a steel driving sprocket and a aluminum driven?
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Farfle   1 MW

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Re: Farfle joins the MENS club

Post by Farfle » Jul 18 2012 11:24pm

Going to wait for the final RPM of the motor before I order, but im pretty set on #40, it's poetry stout, so it should stand up to the hopefully 20+ hp this motor will put out.
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Re: Farfle joins the MENS club

Post by Farfle » Jul 19 2012 3:08pm

AWESOME! laser laminations just sponsored me, the lams are shipping out today. The revised design cut from .35mm m15 silicon steel! Woo!
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Re: Farfle joins the MENS club

Post by bzhwindtalker » Jul 20 2012 4:56am

Very nice! Moar motorz :)

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Farfle   1 MW

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Re: Farfle joins the MENS club

Post by Farfle » Jul 20 2012 10:21am

Heres a pic of the complete "can" . Its got less than a thousandth of wobble, so no vibrations spinning at 3000 rpm.

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Farfle   1 MW

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Re: Farfle joins the MENS club

Post by Farfle » Jul 22 2012 11:11am

Bearings are machined into the sidecovers, and the new axle is pressed into the the sator center.

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Farfle   1 MW

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Re: Farfle joins the MENS club

Post by Farfle » Jul 23 2012 1:20am

BB concentric swingarm pivot is almost done.

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johnrobholmes   1.21 GW

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Re: Farfle joins the MENS club

Post by johnrobholmes » Jul 23 2012 11:50am

That is an outrunner I am most jealous of!!


Those laminations sound slick. You won't be running into much eddy or hysteresis losses, so the motor should stay pretty cool even at 3krpm.

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Re: Farfle joins the MENS club

Post by Farfle » Jul 23 2012 3:01pm

johnrobholmes wrote:That is an outrunner I am most jealous of!!


Those laminations sound slick. You won't be running into much eddy or hysteresis losses, so the motor should stay pretty cool even at 3krpm.
Thanks man, Im going to be lathing a hub, and ordering a few sets of spokes, so keep an ear to the ground on your end.
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Re: Farfle joins the MENS club

Post by Alan B » Jul 23 2012 5:19pm

Farfle wrote:
Thanks man, Im going to be lathing a hub, and ordering a few sets of spokes, so keep an ear to the ground on your end.
Looks interesting. Nice machining work.

Don't machinists call that "turning"?

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Farfle   1 MW

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Re: Farfle joins the MENS club

Post by Farfle » Jul 25 2012 8:50am

yeah, Its called turning. Anywho, heres a mock up pic of the motor :D .

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fractal   1 kW

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Re: Farfle joins the MENS club

Post by fractal » Jul 25 2012 11:27am

nice work!!! is that a dirt bike fork? if so, where did you get the headtube to make a good fit?
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24s 3p Lipo (100v, 15ah)
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24 fet infineon controller made by Lyen, heavily moded by Methods
8awg harness by Icecube57
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Re: Farfle joins the MENS club

Post by nicobie » Jul 25 2012 12:02pm

Looking good!

Nice vise too.
Take it easy... but take it. (Woody Guthrie)

my eTownie build thread: http://endless-sphere.com/forums/viewto ... =6&t=23701
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Farfle   1 MW

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Re: Farfle joins the MENS club

Post by Farfle » Jul 25 2012 12:17pm

fractal wrote:nice work!!! is that a dirt bike fork? if so, where did you get the headtube to make a good fit?
nope, its a Manitou Dorado, you can find them pretty cheap in need of a rebuild, which isn't real hard.
nicobie wrote:Looking good!

Nice vise too.
Its my favorite one :D
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fractal   1 kW

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Re: Farfle joins the MENS club

Post by fractal » Jul 25 2012 12:45pm

Hey Farfle, I'm really interested in your rear swingarm linkage. How did you make it ? Are they all custom made pieces? Did you use a special BB? Bearings, ...etc? Having the swingarm link on the BB seems like a good and simple idea.
Norco A-line DH bike with :
«cromotor/hubzilla» from http://www.greyborg.com/
24s 3p Lipo (100v, 15ah)
Methods LVC/HVC cell level protection system http://www.methtek.com
24 fet infineon controller made by Lyen, heavily moded by Methods
8awg harness by Icecube57
17 inch moped rims with Michelin Gazelle tires by John Rob Holmes http://www.holmeshobbies.com
other stuff http://www.ebikes.ca

details
http://www.helicamguide.com

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Farfle   1 MW

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Re: Farfle joins the MENS club

Post by Farfle » Jul 26 2012 11:44pm

sweet! the new lams are here!

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Re: Farfle joins the MENS club

Post by liveforphysics » Jul 26 2012 11:50pm

Right on! You're one of the very few folks on ES who has had custom lams made. I'm pumped to see it all come together!
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Miles   100 GW

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Re: Farfle joins the MENS club

Post by Miles » Jul 27 2012 12:40am

Great! Looking forward to seeing how this performs.

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Re: Farfle joins the MENS club

Post by nicobie » Jul 27 2012 1:00pm

Those are thin!
Take it easy... but take it. (Woody Guthrie)

my eTownie build thread: http://endless-sphere.com/forums/viewto ... =6&t=23701
Magazine article https://www.electricbike.com/nicks-etownie/

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Farfle   1 MW

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Re: Farfle joins the MENS club

Post by Farfle » Jul 27 2012 1:03pm

The lams are .014" m19 C5 electrical steel, Im hoping it should keep eddy losses pretty low.
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