Make a Backyarders high efficiency electric motor

**SawDustSniffer** · 6th April 2012, 10:29 PM

i was scratching my head , trying to think of something hard to make ( a challenge) , and came up with a High efficiency electric hub motor , google gave me start , the CSIRO has done a lot of research in an attempt to get an Australian UNI to win the " solar car challenge " from Darwin to Adelaide

one of the files i found that was usefull was http://www.ata.org.au/wp-content/upl...ency_motor.pdf

it basic describes the 2 motors , "steel backed magnet" and the "Halbach ring" version that say is over 97% efficient

there 3 phase , out side switched motor , with an internal hall effects sensor
the wired up "stator" is stationary( fixed to the axil ) , while the permanent magnets are fixed to the rim , no brushes

so i looked at the magnets , and there prices , the metal backed motor is do able , you just need to shape the magnets into wedges 20north, 20 south 40per side , 80 per motor

for the halbach ring , there are 4x as many magnets to shape , this time from cylinders as the north/ south has to be angled , and to find cylinder magnets with the polls running at 90deg to the length is near on imposable

so after sleeping on it i came up with a cheep skates halbach magnet , 5mm balls , are dirt cheep , glue magnets to a stick marked north and south , when a ball sticks to it you know its orientation , and you can glue them into position on what ever angle you want ,

but the gaps , are no good , so i came up with , pounding a few magnets to fine dust , and epoxying the dust between the gaps in the balls , with a strong orientated back ground magnet ,to get the dust to sit in the correct alinement

the drawing below is of the mould for the carbon fibre , (every thing is opposite ) all the 1/2 sphere's ( over 800) will take a 5mm sphere magnet , making "Halbach" segments of 9deg arc , with 40 of them per side

my PC went down on tuesday with whats looks to be a motherboard PCIe bussline fail, evey thing else works fine , looks like up for a new mother board , now i have to find an old one so i dont have rechip and ram it (intel Quad duo)

**SawDustSniffer** · 6th April 2012, 10:49 PM

the carbon fibre will be easy ,
i will drill holes to fit nails( brads) every 10mm around the out side of the mould , and run 12k tow carbon fibre in a spoke pattern ( dry) between the nails , pull all of the nails out so the carbon fibre can form the shape , vacuum bag it , then let the resin in " infusion" ( dry layup) carbon composite construction

the photo below is of a roll of 12k tow ( 12000 strands of carbon in flat string ) , these 3kg rolls were on ebay about 3 years ago for 1$ a roll , i got 15 of them with a max bid of $3 on every roll they sold ( about 300 rolls )

**SawDustSniffer** · 6th April 2012, 10:58 PM

the magnets
New 216pcs 5mm Bucky Sphere Magnet Magnetic Balls Puzzle Cube Toy with Gift Box | eBay

5mm spheres of Neodymium magnets , they seem to be the largest bulk / $ you can bye

**Ausworkshop** · 16th June 2012, 08:24 PM

Looks interesting. How is this project going?

**SawDustSniffer** · 18th June 2012, 11:39 PM

got the magnets glued in . have to epoxy magnet dust between them and mill the them flat, so its not assembled yet
, also working on the drive unit , still deciding on making a 3 phase H bridge my self , or use a VDF to drive it ,no regenerative braking on a VDF, just a hot resister

might go down the VFD road , but want to by pass the 240v 50hz rectifier inside so the vdf runs on DC battery's ( yes a 240 volt battery(haven't got that far ??/ 300+volt battery ))

im stoked , asked at the last Darwin too Adelaide solar race , for back yarders to have a category and this week they came to the party , back yarders are in , in the 2013 world solar car challenge ,
if it works , 2015 the earliest

link to the rules for 2013 race > http://www.worldsolarchallenge.org/2...e_wsc/overview

**marco** · 28th February 2013, 08:57 PM

Originally Posted by SawDustSniffer

got the magnets glued in . have to epoxy magnet dust between them and mill the them flat, so its not assembled yet
, also working on the drive unit , still deciding on making a 3 phase H bridge my self , or use a VDF to drive it ,no regenerative braking on a VDF, just a hot resister

might go down the VFD road , but want to by pass the 240v 50hz rectifier inside so the vdf runs on DC battery's ( yes a 240 volt battery(haven't got that far ??/ 300+volt battery ))

im stoked , asked at the last Darwin too Adelaide solar race , for back yarders to have a category and this week they came to the party , back yarders are in , in the 2013 world solar car challenge ,
if it works , 2015 the earliest

link to the rules for 2013 race > http://www.worldsolarchallenge.org/2...e_wsc/overview

How progress? Any pics or have you gone into secretive "im gonna win mode"?

**Ausworkshop** · 8th March 2013, 12:25 PM

Maybe he was kidnapped by an oil company.

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