Mostly PM motor - Joe Flynn motor. My attempt to replicate

[Jetijs]

A while ago I read on peswiki about the Joe Flynn parallel path technology and its potential in permanent magnet motors. I found it quite fascinating. The claim is that the motor should give up to 3.5 times more torque than conventional motors. I thought that it is well worth investigating. Here is the basic theory:





It is said, that you can direct the magnetic flux through a core with a small electrical input. I made the basic experiment with four iron blocks, two coils and two 1"x1" cylinder magnets.



I was pleasantly surprised that so far it works just as claimed. With a short impulse of 4A of current I can manage to direct the flux of both magnets through one side of the armature, leaving the other side completely without any magnetic flux. It does not attract anything, even a hairpin. If no current is passed through the coils, the flux from one magnet flows through one side and the flux from the other magnet flows through the other side. At this time I can pull the iron block away from one side with moderate force. When I energize the coils and all the flux flows through one side of the armature, I am not able to pull that iron piece away anymore, it is more than 2x stronger attracted than before and this is understandable because not only the flux from both magnets now flows through one side, also the magnetic flux from the coils aids this process making the attraction force even stronger. This was great

Ok, after that I ordered some silicon steel motor armature plates to be laser cut. I also ordered 1"x1"x1" cube neo magnets that I will be using in the motor. I decided at first to design the motor plates exactly as suggested on peswiki and if it will work well, I will make a bigger multipole motor.



Now I had to glue the armature plates together so that they could be easier machined afterward. The process is messy, but it needs to be done. I use Bison epoxy metal to glue the plates together. It is rather thick, but I can make it lore liquid using solvent. After that the process is more like baking a cake The best part about this epoxy is that it also dissolves in water while not cured so I could wash away all the excess epoxy then the plates were pressed together:









I made an aluminum base plate to bolt both stator cores on it so that the core poles can be machined smooth in a lathe. I need two of these base plates, but unfortunately the driver of my cnc machine broke down after I cut one plate. Anyway, as soon as the magnets arrive, I will put them in the needed places within the stators, bolt the stators to the base plate and then remove the magnets because machining this core assembly with magnets in is not very wise The rotor will also be machined when the shaft is ready to get the smallest air gap possible. But I doubt that I will be able to get air gaps as small as in my Lindemann rotary attraction motors (0.08mm) at least in this design, because this design puts a big load on the shaft on each phase. In phase one the rotor is being pulled upwards and in phase 2 the rotor is being pulled downwards. If the shaft bends just a bit, the rotor will lock down. Fortunately this is not the case in 6-pole motor where the rotor is pulled in 3 directions simultaneously at each phase.



Here are the CAD drawings of how the motor will look like when ready:

[Jetijs]

I really hope this will work well because I am eager to make the 6-pole motor because it just so happens that I have six 1"x1"x4" neo magnets laying around and these things are so powerful that I am scared to pack them out yet Also I hope that I will be able to recover some of the input energy as the inductive spike that appears when the current is cut from the coils, this has to be verified yet on a small experiment, but if it is possible, then it is HUGE

Here are some drawings of how a 6-pole motor looks like:





I hope that I will be able to get this motor running till the first half of January, for the holiday season almost all machine shops are closed and I can't do everything by myself

I will keep you updated on my progress.
Thanks,
Jetijs

[broli]

I feel happy and sad. Happy because when you take on a project you go all out so this is going to be a very interesting thread. Sad because I and others dream about having the possibilities to build the projects and ideas in our heads with the level of skill and refinement you have.

[rave154]

JET,

i am...... SERIOUSLY impressed !


the level of genius in this place never ceases to amaze me,

JET, Michael J N, GOTO, INQ, BODKINS, FUZZY, LIDMOTOR, etc etc


I bow & humble my self to your tenacity, persistance & unrelenting.....relentness'ness ( is that even a word? )

David. D

[Jetijs]

Thanks guys
And Marry Christmas!

[theremart]

I have found...

When working with the big magnets that wearing leather gloves help to save hands if they do pinch you can slip off the glove. I worked with this sized magnet when building one of my rotors and yep be careful my friend firgers hard to replace.

Merry Christmas Jet, looks like soon you will have your Christmas present :-)

[rickoff]

Excellent photos, diagrams and explanations, Jetijs. You never fail to keep us inspired. Best wishes to you in the new year.

Rick


@ rave154

relentness'ness ( is that even a word? )

No, but 'relentlessness' is, and was probably what you were thinking of. Jetijs certainly pursues the quest for alternative energy with relentlessness.

[mklimesh]

Impressive

Jet,
That is very Impressive (+_+)

Merry Christmas
Mike Klimesh

[Jetijs]

Thanks Rick, Mart and Mike

I was busy today, I fixed the cnc driver and cut the bearing holders out of 8mm thick aluminum. I also cut the acrylic plates that will hold the stator and rotor assembly together.





I also made a quick test to see if there is a way to capture the energy from the collapsing magnetic field and there is. I can capture those spikes in a capacitor just like in my attraction motors so these are some very good news, I don't see why we couldn't use the circuit from the attraction motor in this case, because if this motor can deliver 3.5x more torque than conventional motors, then with a recovery circuit it should be several times more efficient

Thanks,
Jetijs

[Jetijs]

Found an interesting youtube video about Flynn motor. This guy has built several Flynn motors and in this video it seems that he has hooked one up to a load test stand. The video is in bad quality and you can't really see much clear, but if I understand it right, the motor produces 105W of mechanical torque and consumes 1.7A at 31V.

YouTube - flynn motor OU

Now I wont be able to sleep till the motor is finished

[Jetijs]

My magnets arrived today.
I couldn't resist to put them between the stators. Found out that this must be done extremely carefully if you don't want to break apart the silicon steel sheets when removing the magnet. I also found that at the magnet holding places, the silicon steel plates are not perfectly in line with each other, Some plates are up to 0.5mm away from the magnet. I filed those parts smooth as good as I could. After all, what's the point in getting the air gap between stator and rotor extremely small, if there is bigger air gap at the place where magnets touch the stator? Anyway, this will just be a proof of concept model, if it works well, I will build the 6-pole version and wont do such small mistakes again. I put the magnets in place again and bolted the rotor to aluminum support plates, this way I will have the right space between the stators when the poles will be machined smooth. I put the magnets so that the flux of both magnets closes through the stators, this eliminates almost all of the magnetism around the stator and it can be machined safely. If I left the magnets in the other way around as in Flynn setup, then all the magnetism would be at the stator poles and machining such an assembly would not be very wise. Also I ordered the shaft to be machined today. Everything is going smooth so far. Here are the pictures:

[broli]

Very nice work. Could you perhaps add pictures of these parts in your hand to get a good size reference. Because everything seems really big right now.

[Jetijs]

Thanks broli
I can't do that right now because I am already out of the shop, but will add something in the later pictures to compare the dimensions. The magnets are 1" cubes. The whole stator assembly is about 150mm in diameter, that is just a little bigger than a standard CD.

[broli]

Thanks broli
I can't do that right now because I am already out of the shop, but will add something in the later pictures to compare the dimensions. The magnets are 1" cubes. The whole stator assembly is about 150mm in diameter, that is just a little bigger than a standard CD.

Lol you see, I thought this was the size of a washingmachine and thought you were very brave handling those palm sized magnets .

[elias]

Very Impressive

Thanks Jetijs,

You are always an inspiration.
I hope to see your device operating at COP > 1 soon.

Elias