DIY Air Core Axial Flux Motor/Generator
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- Опубліковано 2 жов 2024
- Going a bit more in depth with the different parts of the motor.
Forgive my filming and editing skills. I am still learning
Simulation Generator (Work in progress)
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Really cool project man, would love to see you explore this more. Last year I made an axial flux machine for my master thesis and we used a PCB stator. Very fun to play with and relatively cheap to experiment with once you have a set of rotors. Many different types of winding patterns to try out and we got some very promising results out of it!
Can I have your any other social media contact
Cause I am working on PCB stator motor
Same as you said above
May be your experience Can help me a bit
Thank you
As you could see on startup of the motor, there is an imbalance you should take care of. Balancing the rotor would improve its performance and reduce the vibration.
I agree with Dirk S on the balancing, also adding iron is important as well.
Great video man, stay frosty & keep tinkering!
Nice detailed build, you put in a lot of effort! Ofcourse there's imbalance, it's not an easy project. I look forward to your progress and versions you will come up with! Not using iron does make for a lightweight motor wich also has it use.
I would love to see the generator version. I'm planning to build similar motors/generators for small wind turbines and pumped hydro applications. Subscribed!
I have been wanting to make a good generator for a while now. I will do this soon. I think I need to make at least one more motor stator for a direct comparison. Then the generators.
@@colbyjohnson2344 I think the main issue for a generator is going to be the rpm required to get a decent output which probably implies some sort of gearing... Its difficult to make decent gearing in plastics as the forces that need to get transferred through a relatively small area are pretty big be definition. It might work to use a belt setup with a large diameter for the input and smaller for the generator... Looking fwd to seeing what you come up with! {There are some interesting UA-cam videos of very simple generators -use car bits, etc. Also fascinating to see how they renovate motors in back-alleys of Pakistan!}
Unfortunately they don't make good generators. Not efficient ones anyway. A truly efficient generator is a generator and not a motor. A truly efficient motor is just that and not a generator. If you design a truly efficient motor design it to be just that and not a generator. I'll bet people have no idea why they don't make efficient generators.
Efficient = marine wind turbine is the TESUP Master940 , and similar designs. VERY good at low wind speeds
@@JF32304 You might like these marine wind generators like AIR X MARINE TURBINE. You may need ten for an inefficient house though...
Beautiful motor! Although machining might be expensive, you might be able to use laser cut materials to address the flatness problem you encountered.
Thank you! Yours are very cool as well. Can't wait to see another update :)
Currently the back irons are the only parts that are laser cut. I have thought about chopping up the design into a bunch of laser-cuttable parts, but I think certain parts would just be better off machined as one, specifically the rotor hub. I will definitely do that with some other parts when I am happy enough with the design. It has changed a lot over 2 years, but is definitely slowing down.
Thanks for your interest in the project
Kinda seems like the problem with the thrust bearing is that you have it interfacing with plastic. It doesn't matter how flat you get that, it's the hardness that's the issue. Maybe an inlaid stainless steel washer would fix that if you really need the motor to bear thrust forces directly.
@@whatelseison8970 Agreed, there's a reason why the rollers on a bearing are so precisesley machined, they need to interface with a surace of equal quality/roughness to work properly and a 3d printed surface just isn't gonna cut it.
You might find this useful How to Make a DIY Wind Generator: ua-cam.com/play/PLsT7_jPsZM5oZeMUi5ejGozVTHm83S3-7.html
Especially this one ua-cam.com/video/5NdWQC4hEw4/v-deo.html
Very cool. I have written a lot of these tools they show in my own spreadsheets. But I like the information regarding the blade shape/size. Thank you for sharing
Thanks Colby.
PS, I'm using my private account not my channel account, but this is Clark
After watching videos about axial flux arrangements I configured my pulse motor in this way. WOW, a great improvement over the standard armature. You have built an excellent device, great deal of time and talent.....and money. My stuff would be considered low tech, but it works and one of the motors, so far, is self sustaining, after six months of operation maintaining 8.3 - 9.0 volts on a worn out 12 volt car bat. Will post a vid after the first of the years.
Would love to know that, I have a metal lathe if you don't and could improve your balance/efficiency
@@CraigLandsberg-lk1ep I am sorry to inform you. Our dear friend, almost a year ago now, sadly fell on his shotgun, and accidentally shot himself twice. Please enquire no more. Respect the family's wishes.
@@epochgames3049 I mean, how would anybody know? there's no evidences of that on the channel. Really sorry to see that!
@ganjagardener we know where you live. You put it on your taxes. Stop asking questions.
I'd try building it in aluminum, also with a decent drill press, you would be surprised what patients and a Dremel. And drill press can make, get the aluminum brazing rods, but a drill press, with the small 3"-4" lathe chucks in it, can work similar to a large or mill, using similar cutting tools or a file, you just have to go slow they do not like the side loading, I can imagine some aluminum bar stock, and plate, tap and die set. I think you could make it, also powdered iron and epoxy in a 3D printed moulds, I'd like to build one about 12" and 3-6 layers, like 3-6 motors together, set each up identical, so they can use a single controller, something larger so it could power a small car,
** Also ppl are using car alternators to convert to motors, do you have any interest in that?? Maybe design a better stater,
and/or rotor, the electromagnet rotor is often re built using permanent magnets, in different ways, I thought about just using a small pwm brushed motor controller, use it to vary the field strength, I want to get a newer hairpin alternator to play with. The way they work, being not much over 50% efficient, because of the regulation, they can output 100's of volts, possibly 1000v! But are pwm to limit output, being 3phase outputs a near perfect DC voltage, so bldc controllers can control them if the rotor is magnetized, with about 48-72v it should make decent power, I think it has approximately 12poles, depending on the alternator, and they are basically all built similar, and easy to work on,
It strikes me that a 3D printer is not a million miles away from a 3-axis CNC machine, I would love to own a machine capable of making small aluminium parts!
"Man walks on the moon"....lol
What do you use to run your simulations? I have started to slowly work on my next electric motor project and eventually I'd like to actually make a motor that's actually fairly optimized... as opposed to just throwing together stuff that I have laying around and hope for the best haha.
I use FEMM. it runs with a scripting language called Lua too. Or theres even a python version. I used Lua with JavaScript to make a web app to make simulations more easily. Its not super flexible, and I have not had the time to work on it lately, so I would not recommend using it, but you could look at the scrip that is output to glean some info on how to make your own.
There an... interesting... tutorial by someone on UA-cam here that explains how to use FEMM to make a motor simulation. He is not the most professional, but he does explain things well enough to make your own. Thats how I learned the basics.
So because of the thickness of the copper wire/ windings, if too much load is put on the motor the wires could melt? That's good to know if I heard you right & are correct. I've had an idea that I've had for years, but because of moving lost the space to work on things & billion other excuses, besides I have no clue what I'm doing let a lone the equipment. But this does look fun. You should check out the 3D printed computer fan contest page, where people send the guy their 3D files of fan & go for most silent & best air movement/cooling etc. pretty cool designs that have thrown yet another variable into my idea. :/ :D
Yeah smaller diameter wire will be able to handle less current due to higher resistance. Typically I believe the conductor is chosen based on the current range your motor will experience. Along with other factors, like how its cooled.
I have not heard of the 3D printed computer fan contest, but I'm intrigued. I would love to add an impeller or something to help cool the stator during operation. Thanks for the suggestion.
@@colbyjohnson2344 For CNC there are already servobrushless with shirts that passes water or coolant liquid
To reduce breakage of the wrapping wire, due to the strong accelerations or braking, it also includes the presence of harmonics, creates the stator's void, then injects the heat resin and is centrifuged so as to fill the quarries and skeins
Other trick, the calibrated copper wire is used: the classic thread, the damage of a defined diameter, but unfortunately corresponds to the average diameter on a length of 10 meters .... it can happen to find one or more point with a lower diameter during the Trafilating ... will be the point of breaking the stresses ....
Mr Johnson, would it be possible to 3D print a Raxial Motor using both axial and radial magnetic fields combined to produce a stronger field just like the Quark Motor produced by Koenigsegg? Thank you sir.
You know I have thought about this a lot, and I think it would only make sense with an iron core motor. With the air core, I am trying to shrink the air-gap to as small as possible to increase the flux across the stator, but I think that it would be difficult to position magnets either on the inner or outer radius in a way that would add any significant amount of torque. But I would love for someone to prove me wrong.
@@colbyjohnson2344 I see Mr Johnson. You're probably right, but I had to ask anyway, for sometimes people come up with surprising ways to get around a problem. Thanks for your time and work sir.
Would love to develop a axial no neodimium but riluctance motor that fit into a rollerblade hub, the windings will be made on a pcb would you be interested to try?
That would be really cool, but I have not explored reluctance motors. Maybe at some point I will try something like that, but I have quite a roadmap for my current project. I will probably stick with the PM motor for now.
Thanks for your interest!
That's pretty cool Colby. That it works is huge! I reckon you need a rig to measure actual power out so you can measure the improvements you make.
Keep it up, learning is a wonderful thing. Thanks for sharing this.
This is really impressive Colby. Would making two magnet plates make a lot more power ??? Look forward to more great things from you fella in the future. Nice work Sir.
If I were to stack the magnets it would improve it, yes. I would likely need a slightly thicker back iron, but its possible. obviously it would require twice as many magnets and there are currently 96 in each motor, so I may not try that out of cost alone. I may make larger diameter rotors though.
@@colbyjohnson2344 Colby, how expensive are the extra magnets ??? Drop me a line and I will take care of the magnet cost fella. I am wondering if this motor's efficiency is in the 90 percentile. Reason being that most small motors these days are so inefficient and using them with the cost of electricity skyrocketing will prevent any new way of making an efficient space heating device. That is what I am trying to do Sir. Please let me know what you think Colby. Thanks vf
They have always know how to make Efficent or powerful electric motors.
Its the money buisness.monopoly that produce the cheap nasty in efficent motors for decades...
Its all.about the monopoly that drives buisness.
Making money!!!!
Keep.it up 👍
I've 3D printed a part and then machined smooth surfaces onto that part afterward.
I could turn those parts on my metal lathe for you and send them from Australia 🌏 to the US with not much cost above postage, cause I would like to help you push it to the maximum efficiency and then I could do it for myself, let me know what you think, loving your build video, and I have the tools you need 😅
Shame you are not closer to my location fella. I would machine stuff for you for free. Would not take me long either. Where are you located Colby ??
ProtoPasta makes a Iron Metal-Filled PLA Filament that might be suitable for this project. I believe this is the same Iron-Core based filament used in the Christoph Laimer design.
You would be interested in checking out a new motor concept that produces a high power to weight ratio motor.
It's called a "raxial flux" motor as its design uses a combination of both radial and axial fluxes.
The resulting motors weigh 30kg and produce 330 BHP ; 250 Kilowatts.
Yes I have heard of this, conceptually the idea is not worth pursuing with the design I have made, but I am really interested in the high power to weight ratio. I also think something like a "raxial" would be difficult to DIY, given that I think it would need to be an iron core, which may require a very specifically shaped yoke.
On the cutting edge !! Well Done !! SUBBED
maybe develop to a KickStarter ? (please)
Hi Colby, I have built bigger versions of your motor to use as low head hydro turbine generators. I found that using bigger highest strength (N52?) magnets increased the field over the long air gap.
The other thing is to compress the windings between two flat surfaces while curing the resin. I was surprised how much experimental compression could be used before any shorted turns occurred. Ordinary mild steel magnet backing worked fine, stray flux is not really a problem. I did not use these as the main advantage is low cogging, important for wind but not hydro.
Sounds cool. I'd love to see what you've come up with
This is dope, electric motors are very interesting to me. EMFs are just interesting in general, I mean, we kinda wouldn't be able to see without them right :D
Or feel, or stay together, or live, or even exist. There are only fields.
A very neat arrangement. I'm doing something similar but on a much much bigger scale, where I've found 2 phase to be more efficient on material use. Making a Halbach pattern would reduce this efficiency on materials used but make for fewer stray fields. Keep going and do more videos.
Wow, nice! Halbach and backplated just in case ;) I am trying to find best configuration for the linear pm generator. This gives me hope! May I ask for your suggestion for the project of mine at my channel (last video)? Thanks for sharing and keep it coming!
P.S. What do you mean by placing the iron at inner and outer diameter?
P.P.S. is it me or this could be more efficient if it would be driven in a pulse way? I see some amps jumping every time you start it? Or is it the ampmeter that is going nuts...
Good to see you using back iron. Normal steel works better than cromo for back iron use. Fantastic project motor!
now they are making radial and axial combined .. raxial ... looks awesome
You are going to make me build my own motors! Just kidding, but I had the idea on my head for a long time about designing and building electric motors. Great video with great explanations!! Thanks for the inspiration and for the video, Is PURE gold!
thanky you for the video, keep up the good work. i value those who share their knowledge, and im also passionate about making stuff by myself. im believe you also must have the same feeling as me : when i make something by myself, even if it is delivering 10% of commercial products, it will be more valueable and pleasant for me, rather than buying a brand new of that device from the market.
just a feedback, since i value you; presentation was too robotic and dry, i would love to know the answers of WHY, e.g why you have selected this type of motor, its pros and cons... the the number of wiering ,6, which you said why. also more technical details would be nice, like you have used brass screws, since they are paramagnetic and you don't what them to interact, as you kinda said, but i am talking about other aspects as well.
i wonder if i want to make my own motor, what parameters should i think of, like what will happen if i use thick wires or the effect of more turns and etc...
p.s i know there are many typo ad gramatic errors, but i am too exhusted and my eyes are tiered to read back, just ignore them.
Good feedback. Thank you
Wow wow wow !!....excellent engineering design...next industrial standard
I really want to design a PCB stator, and this looks like the perfect project to build off of.
You might have dips, or uneven highs and lows on the base plate of your 3-d printer that are causing your prints to be uneven or not straight. A remedy might be place your base plate on a perfectly level table top and pour self-leleveling 2-part epoxy over it and allow it to cure into an absolute flat surface. The table must be precisely level. Epoxies like those meant for kitchen countertops might work well. Also by drilling holes through spark-plug feeler gauges you can use them as leveling washers when reinstalling the base plate. However, I don't know if you can print directly on the epoxy. You'd have to experiment. It may require another substrate like butcher block paper covering the base to prevent heat pitting of the epoxy during prints. Probably not in my guestimstion.
interesting ideas. I would be curious how the epoxy would hold up on a heated bed, but maybe epoxy is tacky enough that you dont need the heat at that point. Thanks for the suggestions
Have you considered making stator using PCB (printed circuit board) technology? You can get windings pretty close and accurately positioned. You can use multiple PCBs connected as layers
yes, but I believe these types of motors would struggle to carry a large amount of current, and given that there needs to be gaps between the traces, I think a hand wound motor could be more power dense. I have seen a bunch of PCB motors lately and they are cool, but I have not seen any that claim extraordinary power outputs.
I do think that PCB, or shaped ribbon cables could certainly improve the cost and time to manufacture. I bet there is a certain market and a balance that could be achieved there.
Beautiful motor/generator! Must/could be very energy efficient. I'm new here, will check your other videos now. Keep on developing/experimenting!
maybe some venting, but then you'll have to contend with more dust.. another thing to weigh? nice work tho. balance your damn spinnee part.
I have considered including an impeller, because I do believe that heat is it's worst enemy right now. Going to get the rotor hub machined first then I should be able to effectively balance things. Thanks for the interest
Wow that looks almost made in a cutting edge accuracy despite being a diy. I wish you can make something for an electric motorcycle
True.... however its probably several to tens of thousands of an inch in variation... which is alot compared to a CNCed part it may not be perfectly balanced either since you can see it has some oscillations at certain RPMs.
It is one of the better built axial motors I have seen. I would think he could get a couple hundred watts out as a generator.
I have a dynamic balancer (i make motors) if you want to get the rotor balanced.
I would love to discuss this more. You can find my contact info on my channel. Feel free to reach out.
Is it possible to ditch the iron backing for a Hallbach array with deep inserts, any thoughts?
I understand the theory behind deep inserts, but I have not been able to model a simulation that proves their benefit, so I have not really invested the time or money to try it.
As for halbach array, I am already using it. Obviously my thinner magnets should be larger for it to be more effective, but I believe a back iron will always do more than halbach array alone.
In my simulations I found that using the halbach array and back iron resulted in the best case. I also played around with the thickness of the back iron to get it as thin as possible while still maximizing the benefit
That needs dynamic balancing.
Six very small BRASS grub screws on radial axes close to each edge (three per edge at 120 degrees) of the outside rotor surface should, in theory, help you get there. Good luck.
E Bike and Robotic EVs , Aircraft, Medical Equipments can adopt these Axial motors 👍
Hey, just discovering this and trying to catch up. I noticed that a lot of the axial flux motors available today, the kind you might use in a vehicle application, are rated for crazy high DC voltage, like 300-800v, but yours seems to be pretty functional at 12v. What do you make of this difference in voltage?
I'm getting a CNC machine in the spring and plan on trying to flatter you through imitation... what do you think would make the better material for rotors and stators - aluminum or some kind of plastic like delrin or hdpe?
One last thing - your application of the halbach pattern is really awesome. I mean the amount of work and thought you put into this is inspirational to say the least.
I would certainly be flattered if you made one too!
The reason for a motor in a car being such high voltage, is that it keeps that max current lower for the same amount of power.
The current iteration that I am on has the same iron backing, but the new one has iron all the way to the center. So there is no need for the plastic center piece. Also I have had aluminium jigs cut for the magnets.
And yeah I planned on using Delrin or g10 for the stator center pieces on the next version.
Thanks for the interest!
@@colbyjohnson2344 Thanks so much for your time, I really appreciate it.
I just found your Channel and really enjoy your videos I have subscribed I know we all have busy schedules and I hope that you can find time to post more of your educational videos
Looks super Powerfull! at .5A Really cool.
Son of WoMen Walk on the Moon, Cheers!
i have a few cnc machines and would like to help. i am in southern california, not sure if that helps haha.
My contact information is on my channel, feel free to reach out
Make it work you become a millionaire
Mercedes is making a similar one for a future car. You should try to run a shaft through the center of the stator, and put a rotor on either side, with the stator in the middle. Double the power with very little size increase.
Can you extend the center shaft and add an alternator, in the same design of your invention unit which will convert your generator into a Synergy motor.
This way you will not rely on large batteries for the main source of power.
I have been thinking this type of drive might be good for use in a hub motor and wondered if you have considered that as a good application for the technology.
Very Cool
I enjoyed watching your video, and would like to see whether you could design a real time motor or generator for a ebike or ev . Thanks for sharing your experience.
Take a look at the flux pattern design on the Zero electric motorcycle as they did a lot of R &D on it
Nice project. Thanks for sharing,
Please calculate the torque theoretically as well practically in the next video.
man thats got to be my favorite motor ive seen in a while. i generaly love axial flux motors. youve tried to take out every last bit of efficiency of that little thing and that awesoooome. nice work man. love to see it on an e bike btw
Why can i only like this the once!!
Just awesome :) !!
Don't you think you could get laser cut parts for the discs you mount the magnets on? It should be easy to find a reasonable thickness in some steel with enough permeability. The only problem I see is that you would still need some precision outer rims to get the disc perimeter absolutely flat.
Also - it would be really cool if you could somehow measure the torque vs electrical power efficiency!
The back iron on the rotors are laser cut steel 1.6mm.
I will definitely get torque efficiency measurements and post them when I can
Nice work. I will be following your progression on this. Thanks for sharing.
I have also experimented a bit on this subject and will probably continue at some point but... now I understand why motors are so expensive :D
Awesome. Mind if i post it to the endless sphere Facebook group?
Have you seen Blheli32 esc units with current sensing? Cheaper than a VESC.
Feel free to post on Facebook. I don't use that platform so that would be cool. Thanks!
Nice work! 👌.Subscribed to your channel!
Nice work. It would interesting to know if you have tried one stator and rotor on both side of the stator. Please keep us posted as this is a new area of
I recommend Protopasta's iron filled PLA for motor core design, it prints like PLA but I recommend using a stainless .8mm nozzle instead of a .4 brass one. I am currently also building an experimental motor that has unique operation.
You know.... I have a roll of that sitting around still from a while ago. I was going to make ferrous cores, but that might be a really easy place to start. I have a .4mm steel nozzle. I'll try that. Thanks for the suggestion.
ua-cam.com/video/TfBWD1vP3hQ/v-deo.html
Hi @Anthonyleggio4877, Did you complete the print with iron filled PLA? How is it working, can I try it for 3D printing Axial Flux alternator?
I know this comment is super old, but I had to try asking anyway, when you say motor core, do you mean the Stator?
I enjoyed the video. I own a CNC machine shop, and have some interest in axial flux motors. I have lot of capability to produce machined parts, but I am weak on the electrical side of things. Maybe there would be an opportunity to work together? If you have some interest let me know and we can work out how to discuss further.
@John Morrison, You should find my email information on my channel. I would be interested in a partnership.
Maybe water cool one side of the coils? The one side has the magnets and the other side has the water cooling.
Great project, keep it up!
Nice work. All you need to do now is to refine the making process.
I can help you with the machining. Shoot me a message.
Thanks, but I do not see contact info on your channel. My email is on mine. Feel free to reach out. I would definitely be interested.
Nice build. I was wondering g what kind of coils though.
The motor on my channel was built to satisfy my curiosity only. It uses three coils with 4 turns per coil and 12 poles per coil. It's an axial flux faulhaber wound coil with a cogless iron core, or rather backing.
Colby, you have given your idea - much thanks.
Hey Colby, I'm researching building my own Axial Flux motor. My question is how strong is the 3d printed housing? Even with properly gauged wires, the housing may not be suitable to provide 1/2 horsepower or so. Any comments on that? Love your explanations.
That is really nice,good job on that,instant subscribe.
I wonder if there was a way to put sintered cylinders inside the coils to concentrate the magnetic flux if it would help improve efficiency. Or even a steel (ferrous) bobbin type contraption. This way the magnetic field is directed rather than just a field.
Very cool that it ran so well...did have an odd vibration harmonic...but it ran quite well!
Long term under load does it get hot?
Keep em coming!!!!
Gota feel good you conceived engineered and developed a functional ptototype
What tool are you using to simulate? Thanks.
I use FEMM
I have a machine/wood/composits shop and would be willing to help you machine your parts once you settle on a design....
200K views, and it's your last video. That's sad. Would have been interesting to see all the small tweaks, and how much they effect the efficiency, or make it easier or cheaper to build.
If you ever do come back to making videos, Have you thought about using a Resin 3D printer? IT may be able to give you better tolerances than a standard FDM 3D printer, and could possibly make some of your parts flatter.
Very good. this is an idea i had for some time, i'm gonna build mine too
@colbyjohnson2344 where do you buy the skinny magnets for making the Halbach array?
Congratulations on your creative spirit in this field. At the time of him I had made several experiments on the matter and my opinion and to use not the three-phase but polyphase or two-degree byfase output
, do not insist on the sinus wave form, better tending to square wave without harmonics on the current
The greater efficiency is found when the rotor diameter, the height of the package is
These are my experiences of years of work in the electronic field, however I will follow you with passion, best wishes ..
udos46
i want to see this channel turn into multi-million one. amazing content. keep it up brother.
Very impressive use of modern tools to make a functional DIY power dense motor!
love your work!!!
Great project. As a newbie I have a question: are this strands joined parallel so you have 20x 0.27mm =5.4mm wire or it’s made in series so you have a long wire?
its 20 strands in parallel
try that type of pure dc brushless permanent magnet motor, no ac parts, no commutators, just dc parts, circular coil with non-alternating permanent magnets, pointing either up or down
Should I spend time making, editing, and posting a youtube video that has no interesting results because of a basic 3d printing problem, or get a $150 printer, try again, and then make a video? Hmm, what to do.
Great job! I was thinking this for last 2 years as an e-bike motor project; especially the part about how to implement hallbach array into the axial flux motor.
How did you manage to make an hallbach array? did you order the magnets with a special order?
I did not have to special order. I bought them off of k&j magnets I believe. They only have imperial measurements so I had to just work with that
Add bismuth doped plastic into the air gaps. Tighten up the magnetic field. Just a thought.
Very nice, good work.
Do you have info on the Halbach array/ magnet configuration and coils of your axial flux motor?
Or if you know any other web resources that has good info on this things.
I might try build a similar motor and see if i can manage to make a good one.
can you make a video comparing the torque between a shaft flux motor and a regular radial flux motor of the same size? i read that the torque of a shaft flux motor is 4 times higher than a regular radial flux motor but i don't see anyone making a video comparing them
Nice work, interesting project, subbed 👍
Can the electro- magnet disk be made to move on the opposite direction for Newtons 2nd law, through improvisation of power cable insertion through needle bearings of universal coupling pin ???
Thank you, if read and considered or slanged and trashed.
Rotor needs balancing - really noticeable imbalance as it just starts spinning up from stopped. Get a couple of one axis voltage output accelerometer chip sensors and put them on the top and side of the aluminium extrusion you've mounted it on - sync your scope up to the the rotation of the rotor using just a laser diode module and some retro-reflective tape (the laser diode will self-modulate its own current as the tape comes in and out of the beam, and you can probably trigger on this to move the trigger of the oscilloscope relative the accelerometer signals). That should let you figure out the imbalance.
So far as flatness, get (or make - scrub three tiles, rotating as you grind and swapping between three pairs!) a reference flat big enough to press your mould down onto while it cures. Certainly don't trust printed parts to be flat - they're made with a lot of built-in thermal stress, and will never be all that flat without encouragement when it matters.
How would you say the performance to weight ratio is conpared to a normal brushless motor?
Thanks it's very inspiring, i love the axial flux motor and i plan to build or buy one for project like ebike for example. Just love searching and testing things like you 🙏
Hey, double your output by Using both sides (poles) of all of your magnets by putting another set of coils on the other side of them… try leaving the air cores hollow, non epoxy filled, so that the coils will move a little bit of air to cool themselves… just some thoughts…
Ive been designing exactly this plus more for over 15 years
Have you ever looked at Nikola Tesla dynamic balancing method he used for the bladeless turbine turbine?
This looks perfect for gyro based applications great vid 👌
Where did you get the magnets you used in the rotor?
Me: Uhuh uhuh yup..
You: I used the Halbach pattern..
Me: whaaa, oh no you didn't
Awesome video! We're all learning :)
nice vid - thanks