Brushless motor BLDC 20 kW for electric plane, Test1
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- เผยแพร่เมื่อ 25 ก.ย. 2024
- This motor is especially built for the Thundergull eGull 2000 ultralight plane. For more information check out www.forschungsbuero.de (in German only, use Google translate). Flight tests coming soon...
Having just built my first fully designed alternator from scratch, I really appreciate this. Mine is 6" in diameter (about 4" magnet rotor) and 4" long magnets x 1/2" x 1/2". 16 magnets arranged in NN-SS-NN pattern for 8 poles. 12 coils, using 68 turns each of 17 gauge wire. Each phase is wired in 2x2 series/parallel. It's going to be used for a 7' diameter windmill and charge a large array of parallel li-ion cells at 4.2 volts so there is no cell balancing required. I did some FEM simulations and am aiming for about 36 amps at 250 rpm. I made my own custom silicon steel shims in a horseshoe shape to flow the magnetic flux around each coil. The alternator "frame" is 3D printed of polycarbonate. It's been a very challenging and time consuming to create, but I'm only a few days away from loading testing it for the first time. Right now I'm taking care of some internal shorts caused by my silicon steel digging into some of my coils and it's best I fix it first. Initial voltage readings seems to line up well with my hand calculations using Faraday's law and the peak flux passing through the coil from the FEM software.
@speciway and nos2a2: I made FEM simulations that show up to 100 Nm torque and 2300 rpm. That would mean 24 kW peak. Electrically 20 kW are 72 V and 280 A. Of course this test run has less power. It is only a 11 V battery and no load.
ich liebe alles an diesem Video. Auch 12 Jahre später.
Thanks for your time.
many of the front load washers are using similar motors now, I think the stator core could be rewound and pm rotor , maybe bearings might be used for these type of projects
+65bug519 Please delete comment so people don't buy them all up :)
@@LupusMechanicus True the shakes
You can order the lasercut stator laminations at special steel suppliers. I´ve bought them in Germany, but you´ll also find em in the US.
Thanks, I was wondering what they were called.
@goldocoasto: You have 3 phases U,V and W. And you have 3 corresponding Hall sensors HU, HV, HW. If you change two phases, you have to change the Hall sensors in the same manner.
there's something really satisfying about that hum
Copper windings require more current to opperate as efficiently as metals with lower resistance. I think this motor would work great as a primary DC motor (if that's what your opperating it with) PSE generator.
Actually, they do make clamp on ammeters for DC current. They use hall effect sensors to measure the current.
it is nitpicking as this was a first try however the motor sound sunbalanced, perhaps a better bearing to use is a double roller bearing to minimise the load of the spinning wieght of the prop mount? also I would suggest making the mount from a lighter material or something like the equivalent of the damped flywheel of a crankshaft to help minimise the vibrations from the propeller?
Thanks for share your knowledge with us, can I make a question? What ESC and battery did you used for the test? Thanks again.
What do you do with the center of the lamination once the dies been cut? Seems like a massive amount of wasted material, more then 60% just eyeballing it. Perhaps a series of shrinking rotors? Pls dont tell me you just threw it out.
your battery does not look good, soon may catch fire
Your right ! I almost burned down my travel trailer screwing around with those L-ion batteries.It got red hot and exploded !! It occurred while attempting to connect a power supply without the protective circuit. I learned the hard way that you have to use the same charger that comes with the L-ion battery or batteries. They are more dangerous than lead acid type batteries IMO,so if I ever build or test with L-ion,it will be outside next time. The fumes were horrendous and kept smelling them for days.Funny thing is it got rid of my depression ! lol,just kidding .
Where does one by the stators for motors? im looking everywhere and can only see them being sold in the hundreds or thousands
So thats how you check the amps of the hub experiencing?
If suply is dc you cant measure current with clamp ameter, you need shunt,if its variable frequency then the ammeter is not showing the proper amperage, they are designed for 50 or 60 hz.you have higher requency.correct me if im wrong.
@leaualorin
It´s my own design. I have made some finite element simulations before.
I had a look at the motor you´ve refered to. You are right, it looks similar. But there are some differences also. I use 36N42P and 14 gauge wire and 9" (240 mm) outer diameter. The Fisher & Paykel motor seems to be made for higher voltages.
Wouldn't a smaller geared motor be smaller, lighter and equally efficient?
How did You determined number of magnets and poles and later the position of hall sensors? I am looking for some information and literature but cant find any. And also what material is the best for the core?
awsome motor since it is essensially a 3 phase synchronous motor fed by a variable frequency power supply that is controlled by the hall sensors in order for the frequency to be in step with the motor if a load is applied etc i am not an electronics expert but i do understand electric motors i am an electrical thechnician and studieded all kinds of motors however these kind did not exist hardly when i studied electrical technology back in the late sixties
Thats excellent. 4 of these on a new fiat 500 and your the fastest car around!!!! Woshhhhh
Great but what's the Volts so I can figure out E x I and understand this design better.
How did you make the housing. I need to make one motor but cant make or find it.
Yes rounding the edges of the stator will reduce the cogging effect.
What is the total price needed for making all parts of this motor?
Look up copper wire pricing and steel plates (Silicon laminated), neodymium magnets and aluminium housing.
Measure the dimensions of the motor you want to build and apply it to material costs.
shop around. Buy test samples check quality.
Hello, I like your motor. I design, build and fly with all hand made motors as well. R/C not anything like what your doing. I just had a suggestion for your testing. You can use a simple servo tester/adjuster in place of your receiver and transmitter. These are less than ten dollars and work great. I have a video of how it is used on my channel and I'd be happy to have you take a look. Check out Simple Three Phase Motor Control by DadHav.
Good Job
John
20kw at what voltage? even with enough voltage to reduce the amps to a reasonable level the tiny little magnets will not pull 20kw.
Lol. That battery though? Also can't attain 20kw.
do you have any over heating issues
How much is the battery capacity you used for this
It is sure drawing a lot of amps not even under load!
At 11V and 20A, that's 220W. Nearly 1/3HP
It should not draw that much current. You must have a magnetic cogging resistance causing the increase in current draw. You may want to shape the stator to prevent so much cogging.
Which ESC i can use for this motor?
Thanks for replying
So aus interesse her, was würde ein Motor dieser Größe kosten?
Any suggestions how to change stator shape to make it better?
can you tell me how to reverse correct a bldc motor with hall effect sensor
how do you calculate the coil parameters for a specific motor specs?
Excellent work.
Solo para la prueba! En el avion utilizamos una bateria de 72 V y 60 Ah.
@jabo109k Nope. There is losses in the gears and the gears needed would weigh more then only one engine with no gears would do.
me here again are those rare earth magnets there very powerfull magnets so that will allow a high torque out of this compact motor and this very reliable design shows promise seems low maintenance to me, now if some good reliable powerfull and long lasting batteries are used there is the potential to really start sticking it to the high price of petrolium fuels something has to come along to keep oil companies in line especially avgas too
could you possibly explain your winding techinique there? i see that you have 3 main rings which you have soldered each individual coil to...
They are the 3 grid's, 1 ring for each phase. I had the same idea in building my motors.
Ich mag deine Videos absolut, aber bitte Filme doch wenigstens in 720p, besser noch 1080p mit Mikrofon am Kragen. Ich musste an manchen Stellen nochmal zurück spulen...
Von mir Inhaltlich trotzdem thumbs up !
Please which kind of ESC are you using on this motor, and if you have build it, do you have any idea which ESC is best for a Home made BS. Motor ? I apprishiate your input very much. Thank's
Just make you own. Good learning process
please tell me how much torque & rpm max can that motor reaches
What material is this made of this eletric motor stator?
Hallo !
Wie effizient ist denn der Motor , bzw mit welchen Volt/Ampere wird er befeuert ? ;)
Could you Please tell me what kind of ESC. You are using, and where you have bout it from?
It's very impressive! Did you wind all the coils yourself? How many poles? Or well, I guess it's three electrical poles, since it's essentially a 3 phase motor. But how many magnetic poles?
That LiPo looks a "bit" unhappy (it's swollen) ;)
I work in a machine shop, I would be very interested in building something like this myself, not that I need it though :D
Es sieht gut aus. Was ist der drehmoment pro amperage? Wie viele poles? Volts pro RPM?
nice job man , can you share more information about ESC and battery ? I may intend to use double of these motor for my ultralight
where can I buy the plans for this motor?
Apparently he doesn't reply to any of these posts. I can build one for you.
Where can I get the drawing and data of this motor..
ps: was sind das für magnete? n52? oder n50? wie groß sind sie? und was kosten sie ungefähr pro stück? und wo gibt es sie zu kaufen? freagen über fragen:-)) grüße zu euch aus wien
It looks super. Where did the stator come from? (the part that the windings are made on)
pince amperemetrique sur du courant continu ? tssss
:) Could you please tell me where did you cut lamination steel ?
I have 3 companies that I go to for laminations. Where are you located?
Check eBay for Washer Stator Motor. Ready to use.
Do you know how to use CAD? This is required for making them.
Fantastisch! Thanks for posting!
Very interesting project.
love the sound!!
Nice project! Could you tell something about amplifier you are planning to use?
Hello uncle, I am a student at the vocational college of Vietnam near China, I come from Southeast Asia, I am an industrial electrician, and I want to design an electric motor for cars. pedal, and I don't know how to make it, I have no knowledge of mechanics, turning, metal casting, or AutuCad software ...,
Can you go back to the engine's steel core making process?
We can work together, if you have the skill. Email me. Okekebob@gmail.com
is the stator made of Soft iron low permeability material?
Probably silicon steel. it's typical for laminations.
What is the maximum efficiency of this BLDC?
I hope it's built strong enough that the prop wont pull the motor into two pieces
well how much do you charge for a motor like that?
Not for sale
Part II ???
What price this bldc motor
are you sure that motor have 20kw power?
amazing! Buy a US$ 2 servo tester! Will make your life easy to use airmodel esc to test BLDC
Esa LiPo está muy hinchada!!
That's one puffed up LiPo :)
Thanks for this motor demo, its great. You mentioned you used a standard model aircraft BLDC controller for this test; can you tell me the name of it please?
wieviel drehmoment hat der Motor denn?
How can measure it's 20kw?
wow so ungeduldig, ich hoffe, dieses Flugzeug mit diesem Motor zu sehen! ist um mehr als eine Person besetzt sein?
send me the plans to do and how to get it to plicarlo
Was controller model ist? 20A
can you provide a schematic? is it wired in 3 phase?
I don't know of a BLDC that isn't 3 phase.
He has other videos.
th-cam.com/video/5BXH6GP8mPU/w-d-xo.html
th-cam.com/video/KU1Axy4bVYE/w-d-xo.html
ola,estou projetando um motor deste tipo usando um bldc de maquina de lavar com apenas algumas modificações no rotor.
Welche Magnete sind das?
I am interested in buying one for my para glider. Can u make me one??
Sir you are sooooo cool, I wish you could teach me. I'd love to come to Germany and just pay for private lessons on how to build these motors! do you do any?
I see he never got back to you. are your still interested in learning?
schöne Sache Jungs!!!!!
@MrNeoFromMatrix Nein, dies ist kein Open Source Projekt. Aber ich nehme gerne Entwicklungsaufträge an.
ich will zwei motoren, danke ;-))
+Benjamin Bobo said: "Where does one by the stators for motors? im looking everywhere and can only see them being sold in the hundreds or thousands"
For a one-off job, I'd imagine CNC has made it fairly cheap and easy to have a bunch of laminate sheets cut up, and you just assemble it your self. Pick a material and a cutting technology, then a job shop to turn it out.
You don't buy the laminations pre cut. you have to design them and send the DXF file to a laser cutter and they do the cutting for you. I've had this done many times.
Hello friend, you sell an engine of this? It is exactly what I need for powered sailplane design, 20kw will give me more than I need 25hp. What is the cost and weight of the cell energy this your project? autonomy which time?
You have the pessa of that motor for sale
Very Cool! Need something like this for my one man kit helicopter / monocopter design shown at my TH-cam Helicopter Model 4 Monocopter. Let me know when you start selling this motor.
@forschungsbuero
alright, i´m in love. this motor is perfect for a e-motorcycle. could i see this motor? i life in berlin too, 3km away from your lab
Schönes Motor :)
Hello why 36n42p
i like the idea about brushless motor. one is a problem, bearing ball in the motor will get hot and failure. my idea is, a brushless motor need cool system with an oil.
There are plenty of bearings that deal with high stress, high temperatures and so on.
Capcatrei you knew the car's engine they have used oil to cooling down hot.
as i say, electric brusless motor require too. thank you.
sunghoon ham Did you just use google translate for this reply?
Capcatrei Wow, you speak english.. Bravo, you are my idol! Do you speak any other language?
***** English is not my native language, if that's where you're aiming.
Let see a propellor attached to this motor
take a look at a guy named gerard morin with the right high voltage controler u can use a fraction of the amps it draws and creat more rpm and torque.
amazing
Kongratulations,Wundervoll,Toll,Prima, hier Johann von Chile,please tell me if possible BLDC weight,rpm, torque, cost FOB, controller, and wiring diagram of stator, I am a retired mechanic, but german experience and also Swiss around the globe,makes me more enthusiast to take out solar cells, is not structurally acceptable over the wings,Mit freundliche Gruessen, Herzlich Johann Wegmann,Chilean Air Force veteran,Tschuess
Super !!! :)
Super Motör, allerdings etwas nerviger Sound,
zudem der Keller , schön deutsch
20 kw thats alot of power for sutch a small engine