Sharing ideas on how to make a more efficent motor using Flyback (MODERATED)

[itsu]

Here the overall picture with the 10uF C2 capacitor.
Green trace is the current through Q3 which peaks 10A (5A/Div.)

Notice the not return to zero for the yellow trace.

The DDM across C2 shows 41V DC

Itsu

[itsu]

Here the same picture as above, but now zoomed in on the current.

Itsu

[itsu]

I was trying to see where the power after stopping the rotor (if any) was going to, and therefor i made some input power measurements and temperature measurements
of specific components both when running and when stopping the rotor.

The below table shows that the input (on time only!) indeed increases after the rotor was stopped (6.17W versus 5.15W).
The temperature measurements show where the power went to, see also graph below.

Running    (input 5.15W)                    |   Stopped    (input 6.17W)
--------------------------------------        |   ------------------------
time    20:00       20:30       21:00       |   time  21:30     22:00
                                                         |                   
ambient 19.2°C      18.8°C      19.4°C   |         19.4°C    19,6°C
                                                         |
L1 coil 21.1°C      21.6°C      21.8°C      |         24.5°C    24.7°C
R2      27.1°C      26.5°C      25.8°C      |         30.1°C    30.2°C
L2      20.9°C      20.3°C      20.5°C      |         21.5°C    21.1°C
Csr     20.3°C      19.1°C      19.3°C      |         20.1°C    20.1°C
Q3      24.4°C      24.7°C      25.9°C      |         28.5°C    27.7°C
Q1      21°C         19.7°C      20.5°C      |         21.6°C    21.6°C

So we see 20% more input when stopped mostly going to R2 and Q3, (so current through the shortening MOSFET), L1 and L2.

The 2  555 timers and the MOSFET driver U2 are being fed by a different battery, so not measured by the input.

Screenshots show input power when running and when stopped, the current controller was set to 500mA/Div, so the displayed values for current (green) and power (red) needs to be taken times 50!

Diagram is the present circuit as i have it running with some modifications, like:
R2 = 3.3 Ohm
ZD2 = 15V / 1A
D2 = 1n4002
L2 = 2.5mH
Q3 = irf840
C2 = 10uF (yes really)
Q1 = irf540
csr = 0.1 Ohm / 1%
U1 = not existing (direct from 555 timer via a 50 Ohm resistor)

Video here:  https://www.youtube.com/watch?v=RWihYSKtPuk&feature=youtu.be


Regards Itsu

[tinman]

I was trying to see where the power after stopping the rotor (if any) was going to, and therefor i made some input power measurements and temperature measurements
of specific components both when running and when stopping the rotor.

The below table shows that the input (on time only!) indeed increases after the rotor was stopped (6.17W versus 5.15W).
The temperature measurements show where the power went to, see also graph below.

Running    (input 5.15W)                    |   Stopped    (input 6.17W)
--------------------------------------        |   ------------------------
time    20:00       20:30       21:00       |   time  21:30     22:00
                                                         |                   
ambient 19.2°C      18.8°C      19.4°C   |         19.4°C    19,6°C
                                                         |
L1 coil 21.1°C      21.6°C      21.8°C      |         24.5°C    24.7°C
R2      27.1°C      26.5°C      25.8°C      |         30.1°C    30.2°C
L2      20.9°C      20.3°C      20.5°C      |         21.5°C    21.1°C
Csr     20.3°C      19.1°C      19.3°C      |         20.1°C    20.1°C
Q3      24.4°C      24.7°C      25.9°C      |         28.5°C    27.7°C
Q1      21°C         19.7°C      20.5°C      |         21.6°C    21.6°C

So we see 20% more input when stopped mostly going to R2 and Q3, (so current through the shortening MOSFET), L1 and L2.

The 2  555 timers and the MOSFET driver U2 are being fed by a different battery, so not measured by the input.

Screenshots show input power when running and when stopped, the current controller was set to 500mA/Div, so the displayed values for current (green) and power (red) needs to be taken times 50!

Diagram is the present circuit as i have it running with some modifications, like:
R2 = 3.3 Ohm
ZD2 = 15V / 1A
D2 = 1n4002
L2 = 2.5mH
Q3 = irf840
C2 = 10uF (yes really)
Q1 = irf540
csr = 0.1 Ohm / 1%
U1 = not existing (direct from 555 timer via a 50 Ohm resistor)

Video here:  https://www.youtube.com/watch?v=RWihYSKtPuk&feature=youtu.be


Regards Itsu

Great test Itsu.
But remember one thing-->in order for the waste heat to increase,there first has to be an increase in current. So the rotor is reducing current flow,even though that current flow is what is driving the rotor. The extra heat is just a bi-product of the increased current flow.

Brad

[gotoluc]

WOW Itsu!... that's a lot of data

Thanks for going all the way and sharing it

Most excellent work

Luc