| I had an idea for a radial design that might work.
The primary magnet core is made from steel round stock, center drilled to the shaft diameter and having indents milled for each magnet on its outer surface. A 3" core might support about 4 poles and a 6" diameter should support up to 9 - 2 inch wide magnets. The core length can be adjusted to allow for longer or multiple magnets. (IE each pole might consist of four 1 x 2 inch magnets and used with 10 inch long coils.)
The stator would be constructed from 4 or more plastic plates possibly cut from plastic cutting boards. The outer plates would be cut to support the core/rotor bearings. The inner plates would have a hole cut slightly larger then the core. The inner plates would then have cutouts to wind the wire on. All four plates would be held in position by all-thread once assembled. One or two middle plates might be needed to help keep the wires in place. A thin layer of teflon sheet might work to keep the core magnets from catching the wires.
A secondary idea for the stator would be to wrap the core with wax paper and glue each coil to the outside of this. once all the coils are placed a resin could be used to lock the coils in and allow it to be cast after the core was removed...
It looks to me that the core needs to be made first and the stator second so that the stator can be adjusted to suit the final dimensions...
And now the hard part, finding a large steel slug about 4 inches round and 8 inches long that I can machine..... |
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