DIY Axial Flux 90mm 1.2-2KW Generator Design Recommendations

[offbyfour]

Hello, I am looking to build an axial flux permanent magnet generator and I was wondering if there were any existing designs out there to help get me started. It would be nice for it to be ironless as well but thats not a hard requirement.

The rough specs I'm looking to hit:

Voltage= 48V-60
Power = 1.2kW - 2kW
Rotor Diameter <= 90mm

Finally it would nice if it could use readily available magnets.

 

[A-DamW]

Hello, I am looking to build an axial flux permanent magnet generator and I was wondering if there were any existing designs out there to help get me started. It would be nice for it to be ironless as well but thats not a hard requirement.

The rough specs I'm looking to hit:

Voltage= 48V-60
Power = 1.2kW - 2kW
Rotor Diameter <= 90mm

Finally it would nice if it could use readily available magnets.

Looks like the Lebowski design would fit the bill, other than outer diameter:

Building a triple stator axial flux motor​

​

Origin of the design:

My homemade bicycle motor, version 1​

 

[Roookee]

You can look at kjmagnetics.com or Googlize arc segment magnets or trapezoidal magnets but at first glance it is not cheap. 90 mm OD would probably require high rpm to achieve 2 Kw

 

[offbyfour]

Looks like the Lebowski design would fit the bill, other than outer diameter:

Building a triple stator axial flux motor​

​

Origin of the design:

My homemade bicycle motor, version 1​

Thanks, Ill look into it! Would shrinking the number of poles be enough to shrink the diameter?

 

[offbyfour]

You can look at kjmagnetics.com or Googlize arc segment magnets or trapezoidal magnets but at first glance it is not cheap. 90 mm OD would probably require high rpm to achieve 2 Kw

Ive had a really hard time finding segment or trapezoidal magnets there. Am I just searching for the wrong terms?

 

[Roookee]

Regarding the appropriate terms, I had the same problem than you, sometime arc segment magnets are circumferencial magnets like for outrunners, sometime they are segment magnets for AFPM, trapezoidal is also used to describe the magnets we need for AFPM.
Depend on the company's own terminology. But for sure it is a challenge to find the good one with appropriate OD and ID.
Good luck and keep posting your research, thkss in advance
Cheers

 

[offbyfour]

What do you think about using block magnets in a hallbach array like this:

 

[Roookee]

What do you think about using block magnets in a hallbach array like this:
View attachment 375386

 

[Roookee]

Sorry Offbyfour, According to my very superficial knowledge of electric motors theory I would not d'are to provide any advice.

 

[Roookee]

If you want inspiration for your design have a look at Launchpoint patent WO2011/139396 A1

 

[offbyfour]

So, its taken me a while but I've come up with a design to just see what kind of power I can get. The power density may not be that high but i really want to explore PCB windings.

Could use a design review if anyone wants to take a look at the pcb or mech files:

GitHub - offbyfour/Motor_Axial_Flux: Open Source Axial Flux Motor

Open Source Axial Flux Motor. Contribute to offbyfour/Motor_Axial_Flux development by creating an account on GitHub.

github.com

 

[Roookee]

Congratulations for this project. Regarding the magnets providers you can have a look at dgcourage.com
It seems they can make customized trapezoidal magnets.

 

[Roookee]

Wedge segmented arc magnet is their vocabulary

 

[offbyfour]

Oh nice, that's a good find! MoQ of 1 piece is rare to find. Unfortunately I had already ordered the rectangular magnets so I may have to wait until the next rev to try them. The way its going it may not be that far away haha