The motor is in the design phase and will be an axial flux permanent magnet brushless 3 phase AC motor. The diagram below is a 3D model of the AC motor.
The diagram below is a 2D double sided coreless motor with internal stator.
Check out a 3D motor movie here, once downloaded, select the "Play" option.
Desert Fuel has started to make all of its 3D renderings a reality, the first step is to create the stator which requires an automated winding process. Below is the construction of the winding mechanism. Click on the pictures to enlarge:
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Cut Reel Posts | Welded L Brackets to Hold Posts | Attaching the Reel Posts to the L Structure |
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Completed Reel Mounts | Grinding the Reel Mounts and Stand | Reel Stand Without Guiding Bar and Eye |
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Completed Reel Holder and Stand | Base of the Rotating Winding | Structure Support Structure for Winder |
The motor shaft was rendered in 3D using SolidWorks where it was tested for strength and fatigue to guarantee that it would not fail during testing. The 3D rendering is shown below:
Back of Shaft
Front of Shaft
The 3D rendering of the shaft above needed to be created, the mechanical limitation of Desert Fuel's lathe prompted us to seek outside help. Fortunately, the shaft was created by Tangible Concepts LLC, by a fabrication expert named Mark D. Ewasuk. Mark sculpted the shaft with masterful precision bringing the shaft from the drawing boards into reality! Below are pictures of the process (click on the picture to enlarge):
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Cutting the raw stock down to size. | Turning down the outer diameter of the shaft. | Cutting down the front of the shaft. |
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Finished rough cut of the front of the shaft. | Beginning process of cutting the rear of the shaft. | Final rough cuts on the rear of the shaft. |
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Construction of winding mechanism. | Final construction of winding mechanism. |
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Spinning the turbo generator. | Constructing the windings for the motor. |
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| Winding in progress. | Fine tuning the winding process. |