- Jul 5, 2009
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Re: Re:
There's some low-hanging fruit that can give you more design freedom. Make the axle out of tungsten (twice the Young's modulus as steel) and you can reduce the diameter by a couple of millimeters. Same for the quick release. Use a planetary gear out of nylon and that'll be both very small and quiet. If you want, the magnets can actually form the shell with epoxy filling the gaps. Machine the surface and wrap with a thin layer of carbon if necessary. I'm sure you could also push the boundaries with the bearings (more balls in a smaller race) and live with replacing them more often.
That's just off the top of my head.
From your diagram and my mods to the design, the total internal volume for the motor is roughly pi(27mm^2-6mm^2) x 50mm. That equals a bit more than 100,000 mm^3. What does an off the shelf motor need? First Google hit is Transmotec. http://download.transmotec.com/eng/dc-motors/no-gear/round-type/Transmotec-DC-Motors-0.1W-200W-eng-F.pdf They fit a 60 Watt motor in a package 46 mm x 30 mm diameter. That's 130,000 mm^3. Pretty close considering they use extraneous hardware that we wouldn't include.
And that's for a 24 VDC motor which we would never do. We'd want to go very high voltage and lower speed which should give a boost in power to our design.
So there you go. Zero engineering, back of the envelope says that it's possible.
John Swanson
Nicko. said:Ok, it's time we put our money where our mouths are.ScienceIsCool said:When people say hub, they always think of the shell between the flanges. But there's a relatively big volume occupied by the freehub mechanism... I'd be shocked if a three person team couldn't have a functioning prototype in 6 months. This is something a university student team could do as a school project.
John Swanson
I found a cross section of a Shimano rear hub from som patent link, scaled it to the known width (130mm) and went to work.
I figured you need a quick release. I reduced it to 4mm from the standard 5.
The axle OD I set at 8mm, maybe 7 would work too.
For the hub shell I figured 1mm wall thickness is not impossible, same as 0.5 air gap betweeb hub shell and rotor.
Wheel bearings are spread out as far as possible in the model.
The free hub doesn't need bearings, it can just slide on the hubshell. Mind you, there is no clutch yet.
I put a rotor with 1mm shell thickness on the axle/stator.
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Do you see how the cage and windings would fit on the axle while the rotor holds the magnets on the inside?
No matter how rare your magnets are , it's very far from 'easy'.
And how would you route the power leads to the inside of the rotor+bearings?
What about the 1:30 gear box, is that doable too? It must use two stages, no?
Got an idea for a fully functional freehub clutch that fits in within the standard Shimano profile but doesn't steal space from the motor?
How would you make sure this mechanical masterpiece never breaks down in a public, sensational way?
Maybe you envisoned something completely different. Looking like a standard racing wheel hub of course.
Your call.
There's some low-hanging fruit that can give you more design freedom. Make the axle out of tungsten (twice the Young's modulus as steel) and you can reduce the diameter by a couple of millimeters. Same for the quick release. Use a planetary gear out of nylon and that'll be both very small and quiet. If you want, the magnets can actually form the shell with epoxy filling the gaps. Machine the surface and wrap with a thin layer of carbon if necessary. I'm sure you could also push the boundaries with the bearings (more balls in a smaller race) and live with replacing them more often.
That's just off the top of my head.
From your diagram and my mods to the design, the total internal volume for the motor is roughly pi(27mm^2-6mm^2) x 50mm. That equals a bit more than 100,000 mm^3. What does an off the shelf motor need? First Google hit is Transmotec. http://download.transmotec.com/eng/dc-motors/no-gear/round-type/Transmotec-DC-Motors-0.1W-200W-eng-F.pdf They fit a 60 Watt motor in a package 46 mm x 30 mm diameter. That's 130,000 mm^3. Pretty close considering they use extraneous hardware that we wouldn't include.
And that's for a 24 VDC motor which we would never do. We'd want to go very high voltage and lower speed which should give a boost in power to our design.
So there you go. Zero engineering, back of the envelope says that it's possible.
John Swanson