Holcomb Energy Systems:Breakthrough technology to the world

[Jimboot]

rakarskiy,

Thanks for the good wishes. Looking forward to reading your book.

Since the design approach here is pretty much based on end-to-end CAD CAM EM-CAE, the various approaches
and configurations are varified before ever leaving the computer network. By the time the G-Code for milling and
winding reaches the CNC fab shop there's an excellent chance the device will work as expected and is easily fabricated.

Tasks that are somewhat difficult only involve magnetic material selection and procurement versus costs. Off-the-shelf
items such as wire, housings, hardware cables, recepticals and good quality inverters still seem available with
reasonable lead times and costs.

The various designs are straight forward but CAE analysis can involve long processing times - up to a week or more.
Of great assistance however is the fact that the design is in digital form which is easily modified, as required, while
allowing very easy parameter changes and subsequent comparisons. Reaching the optimum configuration is
accomplished internally by the software. Another bonus is when the design is complete so is all the documentation.

Software development is similar. Using an ST Microsystems Development Board and STM32CUBE toolset combined
with Matrix Flowcode8 (a flow chart type of  microprocessor machine code or "C" programming scheme) provides a
very easy way to write the pulser sequence firmware, and change it if needed. Including the system performance
monitors, LCD GUI and control panel.

A major drawback is you get playing with these devices and it just keeps going and going - the old saying "If you
want to get a product onto the shipping dock and out the door, you'll have to shoot the engineer."

When time permits, hope to look into other schemes such as Figuera. Did Ruslan's device but still no work around
for the instability caused by the variations in the earth's electric field or something to that nature.

SL

What are you milling I thought we'd have to get stamped out electrical steel. I'm looking for local suppliers.

[Beginners Mind]

Novus,

Thanks for checking this out and following up.  IMHO, quite important information,
plus it should clear up any questions.

SL

@ Novus - Big ditto.  Thank you indeed for this! 

[SolarLab]

What are you milling I thought we'd have to get stamped out electrical steel. I'm looking for local suppliers.

Jimboot,

A real short answer - I'm not a materials guy by any stretch nor a seasoned motor/generator
builder - but from my limited knowledge there might not be a need for laminations other than
convience (machining a motor rotor or stator structure might be a bit of a task, even for CNC).

Losses from laminations appear to be greater than for any eddy current losses in
a flat type structure (heat dissipation is abundant re surface area) and using staggered pulses
seems to distribute the eddy current effects. Eddy effects cause heat from current formed by
magnetic fields in the metal. High resistance metals (such as modern silicone steel) reduce this
current.

Also, the cnc mill is used to lay/form the windings, especially the lap coil as well as cut slots in
the pure/soft 3/8" iron plates (rotor/stator). Hedging here a bit in an attempt to avoid the flame
wars from the resident, so-called, experts!     

Still very much a "work in progress."

SL

[bistander]

Stick with laminations.
bi

[Jimboot]

Jimboot,

A real short answer - I'm not a materials guy by any stretch nor a seasoned motor/generator
builder - but from my limited knowledge there might not be a need for laminations other than
convience (machining a motor rotor or stator structure might be a bit of a task, even for CNC).

Losses from laminations appear to be greater than for any eddy current losses in
a flat type structure (heat dissipation is abundant re surface area) and using staggered pulses
seems to distribute the eddy current effects. Eddy effects cause heat from current formed by
magnetic fields in the metal. High resistance metals (such as modern silicone steel) reduce this
current.

Also, the cnc mill is used to lay/form the windings, especially the lap coil as well as cut slots in
the pure/soft 3/8" iron plates (rotor/stator). Hedging here a bit in an attempt to avoid the flame
wars from the resident, so-called, experts!     

Still very much a "work in progress."

SL

Thanks for the clrification,  Milling sounds like an easier route than building a laminated rotor / stator. I thought reluctance & permeability may have been an issue. I've looked at 3D printing in iron then sintering. I'm even considering steel shot in epoxy but I'm still hunting for a more suitable rotor for my existing gen stator.