Things getting done: The beginning of Big Motor

I unfortunately have other things to do than post on the internet but I feel obligated to update this every once in a while so for the maybe one or two people who stumble here by accident so please sit down and enjoy the beginnings of Big Motor (the motor that will supersede small motor). For a scale reference on this motor the air gap OD is 10.5" and the magnets are doubled up to for super poles with 2 magnets per pole, making this a 30 pole 36 slot machine. The model isn't fully done yet, I'm still deciding if I want to attempt getting a second stator of the same type and doing a transverse flux concentrating geometry to avoid magnet reluctance. The attempted result would be a ridiculously high flux linkage and by ridiculous, that is to say something that would just almost saturate the iron with a few 2-5mm of air gap. The operating goal of this linkage would be 1. High torque for low current (hence avoiding magnet reluctance) 2. Avoiding higher harmonics of eddy current losses induced by quickly changing back emf from the magnets (taken care of by the larger air gap). Since these goals are directly at odds with one another some FEMM simulations will be under way to see how achievable this will be. Either way enjoy the picture its Big Motors initial design without any fancy pants transversefluxyness (note: the model isnt done yet).

Big Motor....its big

Power Supply and Vehicle Update

I have been quite busy with school so I'm just going to post some pretty pictures of some of the progress made towards the electric vehicle and power supply. First off here is the transformer. Because I wanted to experiment it is made of a pair of toroids. It is litzed  because this will be run at ~300kHz min making skin depth and eddy currents an issue. The turns ratio is 4:1 and its meant to operate at 120VRMS on the primary side drawing around 10A minimum.

just the primary

with the secondary

The wire is the same stuff used on my motor, its nice because the low gauge makes winding easy, however it has a gnarly polyamideimide coating with astoundingly good mechanical and electrical characteristics coating which much to my chagrin cannot be burned off in a solder pot or removed with standard solvents such as acetone. The easiest ways of removing the coating without a sketchy solvent seems to be sand paper (labor intensive) or propane (not the neatest). At the moment torching it is easiest despite the bits of semi scorched insulation it leaves behind. However to stop the thermal gradient from crawling up the wires and leaving a bunch of damaged insulation I recommend covering the wires in a wet paper towel up to where you want the insulation gone.

On the mechanical side of things I hacked apart a pair of bike frames to be used in the electric vehicle.

Initial bike frame

It is amazing how much less space a bike takes up once it has been reduced to a pile of tubes; even more amazing is the destructive power of a sawzall on a bike frame.

A pair of bikes that were attacked by a sawzall

Next step in this process is to strip the paint from the tubes so they can be cut up and welded together. To strip the paint I got some paint removal discs; they kind of make me think  a brillo pad and bunch of sanding discs tried to have kids. However after trying them out, the process is a bit more labor intensive than I want it to be and so I might resort to chemical methods.

....however work needs to get done so until next time.