Axial Flux Alternator with flux focusing rotors

thingiverse

A fully core-less and yoke-less axial flux alternator. Two magnet rotors are required for this to work. And 32 magnets per rotor. The rotor employs a Halbach Array. The main primary magnets are 25x10x3, which I pulled from a hoverboard motor. The magnets to create the halbach array are 20x10x2.6 which also came from smaller hoverboard motors. If using really fine enamelled magnet wire such as 30 AWG, than twist two strands together, or even three. I used quite a few diff AWG in mine. If using 0,5mm wire, than you should get maybe 60-70 per coil, with 0,4mm wire, about 125, 0.33mm wire, about 175 turns each. Wire the stator in STAR pattern. The coils should come out maximum 5mm thick. Which, they are placed in the ring and flooded with epoxy resin. A spacer is required for the magnet rotors to keep them approximately 5-6mm apart. And an 8 mm shaft rod is used for an axle. And two 8 mm pillow block bearings. And all three parts are bolted together in the middle with M3 bolts and M3 washers n nuts. UPDATE: January 2, 2021 Included a resize able coil core of the exact dimensions of the coil bobbin. Print with Magnetic Iron PLA to increase captured flux for increased performance! Created in Tinkercad by cutting the base off of a coil bobbin half, and filling in the spaces. IMPORTANT. Modify height to match your coils.