![]() When I got the magnets all mounted I had to design the backplate, I made a drawing in AutoCAD and machined on my MPCNC out of aluminum and threaded all the necessary holes to mount the countersunk screws, also I made the center piece out of stainless steel that bolts the aluminum plate to the axle. Once I had that I made a rough design of the 3D printed piece that would allocate all the magnets distributed evenly and printed it with polycarbonate carbon fiber (5.4 mm of total thickness), here's the part:Īnd all the magnets mounted (almost at the limit of being completely pulled away): I've been working on it for a few days, first I searched for a supplier for the magnets and picked a reasonable size to start designing, I went with 24 magnets of 10x10x5mm (N42 grade) and 24 magnets of 10x5x3mm (N45 grade), all of them arranged in a Halbach pattern (24 poles). I would love to build a small buggy/crosskart with my own electric motor. My plans are to make a small motor (like the one you see on the pics, the rotor has 150mm outside diameter), make sure it works the way it should and keep improving from there (and maybe scaling it up). I'm currently studying mechanical engineering and I have a lot of interest on electric vehicles, I've built two electric go karts so far and going strong, also, I spend all my summers working on a electric motor maintenance and repair shop and I learned a lot working there. With its gear ratio freer than before, FLEXWAVE boasts a significantly seamless control of 50 – 120.I've been into electric vehicles for a while, and after reading APL's and HalbachHero's threads I got some inspiration and decided to start tinkering about building an axial flux motor (and found out that i'm not the only one that likes this stuff ). Furthermore, the externally toothed gear, which is made of a highly ductile, thin steel-type material, is deformed with the bearing to mesh properly with the internally toothed gear, making FLEXWAVE’s backlash low. FLEXWAVE, whose externally toothed gear is combined with an internally toothed one, has inside an elastic bearing, whose shape changes ellipsoidally. ![]() Meeting this requirement means to address the issue of backlash, which is created between gears. Additionally, to realize nursing care personnel’s movements accurately, the actuator must be controlled extremely accurately. Even the middle-type, which is for the waste, is only 20mm thick, while the diameter is 90mm. This is why power assist suits’ actuators are required to be thin and compact.įLEXWAVE, a reducer that NIDEC DRIVE TECHNOLOGY started supplying in 2015, is thin enough to meet such requests from nursing care fields. However, at medical care fields, where personnel need to be able to walk narrow passages and walk through narrow door spaces, sufficient caution must be taken to keep actuators’ users from being injured. In principle, any drive component’s actuator has to be large and thick as it is required to generate large power. Using a “shape-changing gear structure” to realize seamless control and a thin actuator Many models have two axes or so (the waste and the knees). Each model has different places to set an actuator on. At present, a single power assist suit costs 600,000 to three million yen. Together, they generate a strong force as the person wearing a power assist suit moves, relieving burden from the waste and feet. Each actuator comprises a reducer, a controlling unit, and a motor, a source of driving force. Their market will soon reach 12 billion yen, and some are estimating it to more than quintuple in the next five years.Īctuators to drive joints are essential components for power assist suits. It is amid these circumstances that the needs for power assist suits, a tool to support physical functions, are on the rise. Japanese nursing care facilities are already suffering from a serious labor shortage, and easing nursing care personnel’s burden is a social issue. Japan’s elderly population keeps increasing, and is expected to reach 30% of the country’s entire population in 2025. Utilize shape-related merits to a reducer-equipped, light, thin, short, and compact actuator. SOLUTION Develop a flat, high-power-density actuator.
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