Axial flux motors

Sure. More layers will allow for more turns. You just want the insulation layer between them to be as thin as possible. I've seen other motors where they stack the layers like that. Also, the copper needs to be thick to minimize resistance.
 
Also you need cores or very thin traces. Wide PCB traces will get huge Eddie losses.
 
Something like this
iu
 
That would be super challenging to build.
You need to maintain a small gap between the coils and the magnets and the magnet forces will be large. You can use steel backing for the outside rotors, but for the rotors in between you may need to use magnets on both sides.
 
fechter said:
That would be super challenging to build.
You need to maintain a small gap between the coils and the magnets and the magnet forces will be large. You can use steel backing for the outside rotors, but for the rotors in between you may need to use magnets on both sides.
Click to expand...

The sum of the push/pull forces experienced by the coils in that design is always zero:
If a magnet is pushing on one side of the coil; another is pushing back equally on the other...

So only the outer 2, magnet holding, steel disks don't have an equal opposing force on them and may need to be made a bit thicker, which is OK as you want field shielding there anyway.
 
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VooteleAer- looks like a tall order to dive into a motor build like that unless you have CNC equipment. Even then daunting as a DIY project. What diameter are you proposing? Did you do any research as to specific costs to have these PCB stators made? Just curious...

mxlemming- (and others with PCB stator interest/experience), is it even feasible to consider an 11-12" diameter PCB stator sandwiched between 2 lightweight Halbach rotors as an integrated rear hub motor, in terms of the low Kv required, torque, cost, and obviously difficult air gap tolerances?

The startup Infinitum and ECM pcb companies are making pretty optimistic claims...
 
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Barncat said:
VooteleAer- looks like a tall order to dive into a motor build like that unless you have CNC equipment. Even then daunting as a DIY project. What diameter are you proposing? Did you do any research as to specific costs to have these PCB stators made? Just curious...

mxlemming- (and others with PCB stator interest/experience), is it even feasible to consider an 11-12" diameter PCB stator sandwiched between 2 lightweight Halbach rotors as an integrated rear hub motor, in terms of the low Kv required, torque, cost, and obviously difficult air gap tolerances?

The startup Infinitum and ECM pcb companies are making pretty optimistic claims...
Click to expand...
There's a lot of companies making absurd claims to take in investment dollars. The reality is that PCBs have a lot of fibreglass and not much copper. Good motors get as much copper iron and magnets in as possible with the least non torque generating stuff possible... So PCB stators are a crap idea for anything high performance, there's no way around it. Sure you could buy some absurdly expensive copper core PCBs... But then you might just be better off laser cutting copper and wedging fr4 between the copper bits...
 
Voot- great that you have CNC. You'll keep us posted if you start building then.

mx- thanks, that's about what I figured. It seemed irrational that you could pack enough copper into that approach without at least multiple stacked stators. Probably ok for small high speed low torque motors...

I'm warming to the idea of winding some copper, as I believe a lightweight spokeless no-cogging axial hub motor to be the hypothetical ultimate ebike motor. As usual, I have some novel ideas for that, but that's a topic for a new thread if and when I pull the trigger.
 
VooteleAer said:
I'm toying with my own axial flux motor design - using segment magnets from Aliexpress
I have an idea to use jlcpcb to make 6-layer pcb coils and stack the rotors/magnets with pcb layers.
Does the stacking, multiple layers make sense electric motor theory wise?
Click to expand...
I actually have an ongoing project with exactly those magnets (past 1 and a half years, but didn't had that much time while studying mechanical engineering), I'm slowly getting back to assembling the whole prototype. I will do a topic once I finish it.
 
Hi ,
For those interested in AFPM, please find the title of a recent global review of AFPM Coreless technology.
Unfortunatly too big to be attached as a PDF, but you should be able to get it with its title on Google
Review Article
Advancements in axial flux permanent magnet machines utilizing coreless
technology: A systematic review
Isiaka Shuaibu a,b,*, Eric Ho Tatt Wei a,b, Ramani Kannan a, Yau Alhaji Samaila

Cheers
Roookee
 
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