3D printed axial brushless motor for drones : one rotor & two stators
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- čas přidán 11. 09. 2024
- Two stators & one rotor axial flux drone motor realization in Laplace Laboratory (Toulouse France).
PhD thesis funded by Région Occitanie.
Research on axial flux motors in partnership whith Santa Catarina University (Brazil) in the project CAPES-COFECUB n°ph930/19.
Actually we are doing some tests and compare it with a trapezoidal magnets rotor to prepare an article for a scientific journal. then we will try a new motor with 3D printed coils. Then we will share the design.
Is the model airplane motor controller only for testing? A proper sinosudial inverter would yield higher efficiency and less heating. Because of the low induction of this type of motor, I2R losses are high when They are just run with a semi 3 phase waveform.
Great work. Out of curiosity why didn't you use delta configuration?
@@Tore_Lund I agree, a mini VESC with FOC would be great.
Are the design files available now?
it's a lot easier to wind your own coils than I thought. this opens up much larger possibilities
Typical motors are probably even easier, but time consuming and you just have to pay attention to directions. I think I would prefer the conventional way, also lower resistance and less soldering.
It’s one of those tasks that seems much harder than people think, to the point most don’t even try. It’s very possible to make brushless motors yourself
Now THIS is PODRACING!!!!!!!
Amazing!!
If I was your thesis opponent I would argue that without having the ferromagnetic yoke filling the inside of the coils so much flux is wasted.
Note that there are iron-loaded filaments if you want to experiment without having access to some metal workshop, although lamination is crucial to limit losses.
For that size, you need to push the continuous power up by a factor of 10 to make it interesting.
but what if you made a combo axial-radial flux motor?
Could you please share some links from where I can understand it's working principle and construction
Looking forward to you stacking these in an arrangement like the multiple rotor cells of a Wankle engine. If you can cross the poles from one side to another side of the stator, why not throw another stator and another set of poles in there. Really cool way of building the motor.
nah screw that, make it an axial-radial flux motor. most torque ever
@@Blox117 yeah, and throw a nuclear reactor in there too
I like your work and close to this would be great yes. How to contact?
Lol, I remember a school visit to a GEC factory in the early 1980's (used to be a household name) and one building was full of people coil winding, day in day out (some for 30 years).It was all very sociable. The building was the size of at least three football fields. It gave me all the incentive I needed to push my interest in programming back then🙂
Dois professores brasileiros... Que orgulho, pena nosso país ser da forma que é.
é mesmo!
Thats what i call engineering , any layouts and mesurments to build such powerful brushless motor ?
Hi, this is the sort of 'sleeves up' engineering to get excited about when you think of all the future possibilities of the axial flux design in EVs and eVTOL/Aircraft, well done!
Have you looked into the relative merits of having a single coil layer in the centre and dual ring of permanent magnets? Also what about filling the magnet core -why coreless?
In industrial developments the 2 rotors & 1 stator version seems to be more efficient because the magnetic flux goes more straight between two opposed permanent magnets, which results in higher magnetic flux for considerably shorter magnets. It is also possible to increase the magnetic flux further by use of an iron ring plate at the opposite side of the permanent magnets to the coils as a magnetic flux guide between each pair of permanant magnets.
Definitely easier to assemble :-). Looks like they might have tried the ring plate in the last test, seems it was of benefit here as well.
2 brasileiros hein que orgulho!!!
2 brasileiros que orgulho!!
Now you should make them into modules so that you can bolt multiple motors together For more torque. Good work super Cool!!!!!
too much torque, gearbox will take care of it
very nice love it ,looks like theres some pure engineering in it
Que buen motor, dos estatores, trifásico, y un torque muy alto y altísimas rpm. Felicitaciones y gracias por conpartir.
Twin stators, an excellent idea.
Great work. I would also like to build such an engine. Is there a building instruction for it?
Beautifully designed and executed!
it actually gave me goosebumps
,
It's beautiful as well as functional, bravo!!!
Would you mind making videos explaining the concepts and procedures? I would like to know if it is possible to cnc the pieces and which materials would be appropriate. This is amazing and really good content.
Awesome! Great shop too.
That's pretty damb amazing! Nice job man!
This is really not a great design. You've got nothing to try to direct and concentrate the magnetic flux through the stators. Ideally, you'd have one stator and two rotors with each rotor having an iron backing behind the magnets on the outermost sides (unless it's a Halbach array in which case you do NOT want a steel/iron backing on the rotors. You want the rotor magnetic fields to be attracting the rotors together around the stator. This does offer a mechanical design challenge, but you'll have MUCH better field interaction with the coils.
I'm not an expert, but I also thought that without another rotor, half of the magnetic field created by the coils goes to waste. Ideally you'd have the cooil stator sandwiched in between two rotors with magnets
@@onemanmob6756 This is mostly correct. Not entirely, but enough to make something that fuctions a lot better than what's shown in the video.
Clever. All you need now is the miniature version.
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Was there a design constraint for single stator? I would think power density would be much greater for dual stators in Halbach array. But in any case, great job!
True
Hi
probably, i mean hes doing it by hand
yeah its awesome when you to got all the tools and gadgets and knowledge to make it ;-}
Super travail. C est formidable
Beatifull, only think is wonder me that putting magnet into plastic case and rotate it with high speed doesn't bother you.
get this into the hands of the public as fast as possible. release the plans and get more fame than Linus Torvald.
80W out of 330g of electrical motor? And this should really go into a drone? Standard brushless motors these days come with more power at a third of the weight. So, where is the gain?
Why are there no magnets on both sides?
Really great work!!! I’m curious, have you or anyone working with Axial Flux design tried also putting magnets on the edge(circumference )of the rotor and corresponding windings around the edge (circumference) of the housing? Or vice versa, magnets on outer edge of housing with windings on the edge of the rotor. I ask because because it looks like that would give you the best of an both worlds(Axial -Radial Flux). I looked around around the internet and didn’t find anything like what I’m suggesting, though I have seen a couple Rad-Axial motors.
Congratulations on the success of such an undertaking and can’t wait til your next design hits you tube. Thanks for the video.
Superb video very nice ❤️❤️
I love diy in this category
Cool build
Does anyone know how to calculate optimal BLDC motor efficiency? Like how many coils and how many poles, coils and how many windings. If prop and battery and TWR are fixed, then how would we get the optimal motor design? Also would the type of bearing also factor in?
جزاكم الله خيرا اخي الكريم وبارك الله فيك وهداك
on 5:32 shows a wye/star configuration scheme of this dual separated stator junction, my 1st question is how it's scheme to make it delta?, 2nd any significant different in speed and torque if it's wired in delta configuration?
If only EVs would sound like this
2 questions:
How well does I work as a generator?
What if you had an even number of coils and odd number of magnets or visa versa?
They don't make good generators. A truly efficient generator cannot be a motor and vise-versa.
Genuine question from a layman - why is the motor noisy? With only one moving part, is it caused by the bearing or air resistance?
Good great job very nice. Thanks
GREAT !!
How does this design approach compare to MAGNAX ?
Out power 80 W, in power about 100 W. Efficiensy 80/100 = 80% ? Very good result if take account the coils w/o iron core.
@@platinumsky845 Maybe. Maybe. I cannot appreciate
Actually for a electrical motor that is quiet poor most motors get above 92% mandated by NEMA some years ago.
Nicely done!
Can this be used as an alternator with any modification such as a metal yoke behind the coils?
Correct me if im confused but those magnets appear to be oriented axially to the shaft, not radially. The field would be perpendicular to the shaft if it was a radial flux motor. No? Or are those diametral magnets?
Brilliant work, what's the music by the way?
Really cool stuff....
Where is the position sensor..???
3 phase ac sychronous motors use?
Would you mind if I could get the 3D printing model file, please?
If i make It half the size, in your opinioni It Will be Powerfull enought to power a small RC plane?
Nice build, but for a drone, this motor would be way to big and heavy compared to its power output. There are motors in the same torque and RPM range with higher power output and weight less than 50g. Saving weight is key in a drone application.
I see you used a 6:8 coil to magnet ratio, just for ease of build? Can you predict performance of motor with this ratio even before the build?
amazing ......introduce water cooling as well and it is ideal for electric vehicles......!
all the care and love and prime materials and meticulous finish then @ 5:00 you go and solder the wires to the pins... that are mounted on a prototype board held with wood screws. It's like you were in a rush to finish. What happened there?
Coarse threaded screws work really well in 3D prints. Machine screws need heat set inserts or the threads wear out quickly.
What is the motor diameter? And does this design good for heating issue?
Has no one heard of heating the enamel with a soldering iron. 400 degrees Celsius is all you need. You can tin it at the same time.
Thank you so much for exposing the full process of construction. Could you also share the files to print the 3D parts?. Many thanks in advance.
Très bien mais pas de lien gihub pou faire un DL pour pouvoir faire un clone DIY et bricoler sur nos modèles réduits ?
Alucinante😊
great work!
cool work
thanks a lot, very interesting.
do you think i can a 3d printed generator coils without core ?
at 7:58 the mechanical power output should be 0.15*7000*2*π/60=109.95 Watts. What is that 80W permanent power supposed to be?
What field did you have to study in order for you to obtain this skill in electronics?
Good work 👍
Could you put the wiring schematic in the comment section? I believe I understand the general idea. With the wiring schematic, I will know for sure. Thanks Really good video.
Can this motor be used as a generator and if so, what advantages are there with two stators instead of one?
essa é a parte mais difícil, medir o torque que um motor consegue produzir.
Hey can you help me make and design a different but close style motor?
Formidable.merci
okay, you're 3d printing parts to build an axial flux motor - what's the thesis arguing?
I think it is more of an investigation to get a baseline for how an axial flux motor without any kind of iron (electric steel) core performs relative to how it might perform with an iron core
Is there any way to get the diagram to make one how much would the donation be
okay the Copper Why Not Plats instead of wire
Pero, si soy solo aficionado, y lo quiero implementar, como lo hago.
Do you have the designs for this motor? would you be willing to share? I would recreate and post a review video with my input as a mechanical engineer
Not a single question about melting the plastic stators.
great project - so 0.24 kw/kg, so 100 kg motor will be 24 kw, this does not sound very promising. but its a great start, you will need to find more powerful and lightweight magnets.
how do you prevent them from getting hot?
how much is the efficiency reduced by not using iron cores inside the coils?
Кпд увеличивается 100%
hello , can you pelase share the CAD model for this motor please @Dominique H
Buen trabajo
I refuse to watch videos that use music as filler. The video could be the secret to the universe and 20 seconds in I fast forward 4 or 5 times, find music at all the fast forwards and I bail ... Seemed really interesting but I will never know.
Any way we could get the models and materials?
@Dominique H How did you figure the number of magnet wire turns for coil???please I look forward to your reply thank you.
Imagine putting a high efficiency Tesla Turbine in-line with a high efficiency axial flux... generator?
assuming we ever obtain the material strengths required, 😅
Is there is any web link for complete PDF from you?
Csn you please tell me, what will be the thickness of your wire which you used in this project
0.6 mm
@@harribeydom and how many turns have u done
@@harribeydom Thank you how can i do all this calcualtions do you prefer any book or any other resource
@@dipeshnangle4414 22 turns. We have multiphisics software like Jmag or Maxwell.
can i gent the link to the paper
Hi, can I get these for experiments.
a metal nucleo for coils not turns more efficient ?
Yes the torque is 20% better but the weight 20% higher. it's a choise!
what app do you use?
thx for sharing
شيئ جميل وممتاذ
I enjoyed a great video let's be friends. 🤩🤩🤩🤩🤩
우리 친구 해요.!!!~~^^
Print with ceramic ?
stl´s? :)
Great work sir and i have a question that which type of motor is good in terms of efficiency and power output for a given volume, radial flux motor or axial flux motor ( bldc)
Generally axial will be higher efficiency because you can stack rotors and stators in a tighter space.
the best is axial flux
axial flux
liquid cool it if you need much more power for small size.
Size of wire (swg)
Looks complicated. Why not try the same design with a metal stator?
the difference on the torque and so on the weight is 20% higher. it's a choice.