Re: [Emc-users] Outrunners

2012-02-25 Thread andy pugh
On 25 February 2012 02:55, Jon Elson el...@pico-systems.com wrote:

 The effect of this is (I think) that the back-emf is very small, and
 the current very high, for a given torque.

 HUH?  On a permanent magnet motor, the back EMF is determined entirely by
 the magnets, and will be the same with or without driving current.

The back-emf in any particular field winding will be independent of
the current, but the field windings which are driven by the H-bridge
at any one time will be different between a properly commutated bldc
with a 90 degree phase shift and one being driven effectively as a
low-pole-count infinite-microstepping stepper motor.

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Re: [Emc-users] Outrunners

2012-02-25 Thread andy pugh
On 25 February 2012 10:15, andy pugh bodge...@gmail.com wrote:

 The back-emf in any particular field winding will be independent of
 the current, but the field windings which are driven by the H-bridge
 at any one time will be different between a properly commutated bldc
 with a 90 degree phase shift and one being driven effectively as a
 low-pole-count infinite-microstepping stepper motor.

Thinking further, whilst I think the above is correct, a bigger effect
might be that a VFD runs at a fixed current and a speed-controlling
PID in LinuxCNC can only vary the frequency (which increases torque at
a constant load speed in an induction motor, but doesn't in a
synchronous motor, which can only lose synch if drive frequency  and
spindle speed don't match). In the case of a bldc drive the PID loop
varies the current (and it will typically be low at low load) and the
field is always in synch.


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Re: [Emc-users] Outrunners

2012-02-25 Thread Lars Andersson
 100K / 60 * 2(poles) = electrical rpms.  You'll need to run the pwm
 well over 100Khz to do this. The lowly dspic33f mc motor series will
 struggle to do this, let alone any additional processing.

My thought was to not run PWM but only direct switching at a base frequency
of a few kHz and without any sensing of rotor angle.
The rotor will run well once it is locked in to the rotating field from the
stator. Crude, but it works. 

 What is the reference to ancient times?

The BLDC core design is perceived as a very late principle but the basic
design with a constantly magnetized rotor and a three phase excited stator
is very old. Of course hall sensors and MOSFET H-bridges came in a little
later than 1910.
 


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Re: [Emc-users] Outrunners

2012-02-24 Thread Lars Andersson
While 10 RPM is pretty impressive mechanicalvise, it is only 1700 Hz on
a two-pole motor. A BLDC is similar to a syncronous three phase motor that
was used much for really high power apps in ancient times, maybe even today.
Typical example is a city water supply pump. They had to be brought up to
the right speed before being connected to the supply, they were not self
starting.

You can run a BLDC from a dumb fixed frequency three phase supply if only
you can get it to spin in the first place.

// Lars 



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Re: [Emc-users] Outrunners

2012-02-24 Thread Erik Friesen
100K / 60 * 2(poles) = electrical rpms.  You'll need to run the pwm well
over 100Khz to do this. The lowly dspic33f mc motor series will struggle to
do this, let alone any additional processing.

I think there is something else though, it seems that a bldc has less
torque from a fixed frequency than a sinusoidal wound 3 phase, but I don't
really understand it completely.

What is the reference to ancient times?

On Fri, Feb 24, 2012 at 12:30 PM, Lars Andersson l...@larsandersson.comwrote:

 While 10 RPM is pretty impressive mechanicalvise, it is only 1700 Hz on
 a two-pole motor. A BLDC is similar to a syncronous three phase motor that
 was used much for really high power apps in ancient times, maybe even
 today.
 Typical example is a city water supply pump. They had to be brought up to
 the right speed before being connected to the supply, they were not self
 starting.

 You can run a BLDC from a dumb fixed frequency three phase supply if only
 you can get it to spin in the first place.

 // Lars




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Re: [Emc-users] Outrunners

2012-02-24 Thread Erik Friesen
Of course, if you use hall effect sensors it would be easier.  Some folks
add hall effect sensors to outrunners, it works fine.

On Fri, Feb 24, 2012 at 1:08 PM, andy pugh bodge...@gmail.com wrote:

 On 24 February 2012 17:30, Lars Andersson l...@larsandersson.com wrote:

  You can run a BLDC from a dumb fixed frequency three phase supply if only
  you can get it to spin in the first place.

 It will probably start from rest, certainly with a soft-starting VFD,
 and will run synchronously.
 However, running synchronously the phase lead will depend only on
 load, and will be very small. The field will be almost 100% direct and
 zero quadrature.
 The effect of this is (I think) that the back-emf is very small, and
 the current very high, for a given torque.

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 wrong.


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Re: [Emc-users] Outrunners

2012-02-24 Thread Jon Elson
andy pugh wrote:
 It will probably start from rest, certainly with a soft-starting VFD,
 and will run synchronously.
 However, running synchronously the phase lead will depend only on
 load, and will be very small. The field will be almost 100% direct and
 zero quadrature.
 The effect of this is (I think) that the back-emf is very small, and
 the current very high, for a given torque.
   
HUH?  On a permanent magnet motor, the back EMF is determined entirely by
the magnets, and will be the same with or without driving current.  The 
BEMF will
be exactly proportional to RPM.  That's not the case with an induction 
motor, of course.

Jon

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Re: [Emc-users] Outrunners

2012-02-23 Thread Peter Georgi
Hi Kirk, saw that you are strugling for outrunners for model air planes,
cars or boats. Look at http://www.hobbyking.com/hobbyking/store/index.rc for
quite good and afordable motors and ESC's. The number of rpm's depend on the
type of motor and the aplyed voltage. You can calculate this by multiplying
the voltage with value of kv (e.g. 1024kv). For the ESC take one that has
some reserve, meaning when the motor takes a maximum current of 60A take an
ESC for 80A continuous or more. Cheaper motors also have cheaper bearings.
Some motors have a fan mounted on the housing. These are normaly designed
for helicopters, because in a helicopter you don't have a cooling air
current. Just as an example
http://www.hobbyking.com/hobbyking/store/__9021__Turnigy_Typhoon_450H_2215H_
Heli_Motor_3550kv_450_class_.html.

Regards Peter

-Ursprüngliche Nachricht-
Von: Eric Keller [mailto:eekel...@psu.edu] 
Gesendet: Donnerstag, 23. Februar 2012 00:22
An: Enhanced Machine Controller (EMC)
Betreff: Re: [Emc-users] Outrunners

On Wed, Feb 22, 2012 at 4:34 PM, andy pugh bodge...@gmail.com wrote:


 Bear in mind that cooling might be inadequate without a huge propellor 
 on the front, so expect to derate.

 RC cars use inrunners with heat sinks, so air must not be an absolute
requirement.  Probably a good idea though Eric

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Re: [Emc-users] Outrunners

2012-02-23 Thread andy pugh
On 23 February 2012 19:56, Kirk Wallace kwall...@wallacecompany.com wrote:

 If I where to stick with an outrunner solution, one thing comes to mind,
 I could get a kit and wind the motor for 220 and use a VFD.

Can you? I thought they were brushless?
A VFD will rotate them, but the phase lead will be about zero, so the
efficiency will be awful.

A flux-vector VFD _might_ be enough like a sensorless BLDC controller
to work, I wouldn't know about that.

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Re: [Emc-users] Outrunners

2012-02-23 Thread Lars Andersson
It has been mentioned in this thread already, but I think it can be
clarified.

Outrunners when they appeared were a blessing for the R/C plane builder,
since a propeller wants to run at speeds below 10 000 RPM for best efficency
and earlier motors did maybe 20-30 000 RPM so they had to be geared. The new
outrunners had the torque already at lower RPM so no downgearing was needed
anymore.

For PCB milling on the other hand with carbide bits of 0.3 mm dia or so you
cannot get to much RPM really, 50-100 000 RPM is desirable to get a decent
cutting speed. This is not what outrunners are optimised for. You would be
better off with a long narrow inrunner of the same power as the short fat
outrunner.  

// Lars


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Re: [Emc-users] Outrunners

2012-02-23 Thread andy pugh
On 23 February 2012 21:04, Lars Andersson l...@larsandersson.com wrote:

 For PCB milling on the other hand with carbide bits of 0.3 mm dia or so you
 cannot get to much RPM really, 50-100 000 RPM is desirable to get a decent
 cutting speed. This is not what outrunners are optimised for. You would be
 better off with a long narrow inrunner of the same power as the short fat
 outrunner.

You can probably bury the motor up inside the taper too, for a nice
big heat-sink.

Were you going to use external bearings, or rely on the motor bearings?

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Re: [Emc-users] Outrunners

2012-02-23 Thread Stephen Dubovsky
Another advantage of inrunners is that you can directly cool the stator
which is where you're generating all the heat.  On bigger motors (Im
talking from forktruck/golfcar motor size experience), DC armatures had a
similar problem (as outrunners).  You're dumping a lot of heat into
something thats impossible to heatsink.  It was a lot easier to cool the
separately excited dc stator since you can simply fin the motor housing.
AC motors, both PM and induction, can be designed so there is very little
heat in the rotor that you have to get rid of.
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Re: [Emc-users] Outrunners

2012-02-23 Thread Kirk Wallace
On Thu, 2012-02-23 at 20:10 +, andy pugh wrote:
 On 23 February 2012 19:56, Kirk Wallace kwall...@wallacecompany.com wrote:
 
  If I where to stick with an outrunner solution, one thing comes to mind,
  I could get a kit and wind the motor for 220 and use a VFD.
 
 Can you? I thought they were brushless?
 A VFD will rotate them, but the phase lead will be about zero, so the
 efficiency will be awful.
 
 A flux-vector VFD _might_ be enough like a sensorless BLDC controller
 to work, I wouldn't know about that.
 



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Re: [Emc-users] Outrunners

2012-02-23 Thread Kirk Wallace
On Thu, 2012-02-23 at 20:10 +, andy pugh wrote:
... snip
 Can you? I thought they were brushless?

They are.

 A VFD will rotate them, but the phase lead will be about zero, so the
 efficiency will be awful.

Maybe that's why it didn't work when I tried using a VFD on a normal
brushless motor.
 
 A flux-vector VFD _might_ be enough like a sensorless BLDC controller
 to work, I wouldn't know about that.


-- 
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http://www.wallacecompany.com/machine_shop/
http://www.wallacecompany.com/E45/index.html
California, USA


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Re: [Emc-users] Outrunners

2012-02-23 Thread Erik Friesen
I doubt any vfd would handle high rpms anyway.  I think you would need to
stay with a 2 pole for those rpm's, or you would have to have a pretty
fancy driver.  Bldc's aren't the right wave shape for vfds.

On Thu, Feb 23, 2012 at 7:46 PM, Kirk Wallace
kwall...@wallacecompany.comwrote:

 On Thu, 2012-02-23 at 20:10 +, andy pugh wrote:
 ... snip
  Can you? I thought they were brushless?

 They are.

  A VFD will rotate them, but the phase lead will be about zero, so the
  efficiency will be awful.

 Maybe that's why it didn't work when I tried using a VFD on a normal
 brushless motor.
 
  A flux-vector VFD _might_ be enough like a sensorless BLDC controller
  to work, I wouldn't know about that.


 --
 Kirk Wallace
 http://www.wallacecompany.com/machine_shop/
 http://www.wallacecompany.com/E45/index.html
 California, USA



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[Emc-users] Outrunners

2012-02-22 Thread Kirk Wallace
I want to mount an outrunner (or other) to a NMTB40 tool holder to try
some circuit board routing. I like the outrunner form because it looks
like the motors seem shorter for the same power. I haven't flown model
planes for over twenty years so I've lost my feel for sizes and
capacities. Does anyone have any experience with outrunners for milling
applications? I'm looking at getting a cheap motor to experiment with
then build on the experience, so the motor will need to be in the
disposable price range.
-- 
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http://www.wallacecompany.com/machine_shop/
http://www.wallacecompany.com/E45/index.html
California, USA


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Re: [Emc-users] Outrunners

2012-02-22 Thread Claude Froidevaux
Le 22.02.2012 21:48, Kirk Wallace a écrit :
 I want to mount an outrunner (or other) to a NMTB40 tool holder to try
 some circuit board routing. I like the outrunner form because it looks
 like the motors seem shorter for the same power. I haven't flown model
 planes for over twenty years so I've lost my feel for sizes and
 capacities. Does anyone have any experience with outrunners for milling
 applications? I'm looking at getting a cheap motor to experiment with
 then build on the experience, so the motor will need to be in the
 disposable price range.

for PCB routing, inrunner will be better, as you need as much speed as 
possible (40k to 100k rpm). I do some trials by the past with a cheap 
inrunner, abd even without load the temperature rise was too quick to 
allow any real use. I was strongly suspecting the VFD, as cheap as the 
motor... but I never spend more time on it, I got a 24'000 rpm spindle 
that is OK (but way too slow to make fast routing)

I'm right now waiting for a chinese spindle than must reach 60'000 rpm, 
will see, this shall give a big up to ma PCB routing speed.



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Re: [Emc-users] Outrunners

2012-02-22 Thread Erik Friesen
You could take a look at the marine applications (inrunners), there are
some water cooled.  What will your supply be?  You'll want to decide what
rpm you want to run, as the higher kv, the lower the torque.  Are you going
to belt drive, or direct drive some way?

On Wed, Feb 22, 2012 at 3:58 PM, Claude Froidevaux men...@bluewin.chwrote:

 Le 22.02.2012 21:48, Kirk Wallace a écrit :
  I want to mount an outrunner (or other) to a NMTB40 tool holder to try
  some circuit board routing. I like the outrunner form because it looks
  like the motors seem shorter for the same power. I haven't flown model
  planes for over twenty years so I've lost my feel for sizes and
  capacities. Does anyone have any experience with outrunners for milling
  applications? I'm looking at getting a cheap motor to experiment with
  then build on the experience, so the motor will need to be in the
  disposable price range.

 for PCB routing, inrunner will be better, as you need as much speed as
 possible (40k to 100k rpm). I do some trials by the past with a cheap
 inrunner, abd even without load the temperature rise was too quick to
 allow any real use. I was strongly suspecting the VFD, as cheap as the
 motor... but I never spend more time on it, I got a 24'000 rpm spindle
 that is OK (but way too slow to make fast routing)

 I'm right now waiting for a chinese spindle than must reach 60'000 rpm,
 will see, this shall give a big up to ma PCB routing speed.




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Re: [Emc-users] Outrunners

2012-02-22 Thread andy pugh
On 22 February 2012 20:48, Kirk Wallace kwall...@wallacecompany.com wrote:
 I want to mount an outrunner (or other) to a NMTB40 tool holder to try
 some circuit board routing.

Bear in mind that cooling might be inadequate without a huge propellor
on the front, so expect to derate.

-- 
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Re: [Emc-users] Outrunners

2012-02-22 Thread Kirk Wallace
On Wed, 2012-02-22 at 16:18 -0500, Erik Friesen wrote:
 You could take a look at the marine applications (inrunners), there are
 some water cooled.  What will your supply be?  You'll want to decide what
 rpm you want to run, as the higher kv, the lower the torque.  Are you going
 to belt drive, or direct drive some way?
... snip

The supply will be whatever it needs to be. I don't think torque would
be a problem because the etching bit will most likely be small at the
tip. I suppose the RPM will need to be in the 100k range to get decent
cutting feed rates? I have model car motor I used for drilling circuit
boards which worked well. I want to mount the motor on axis with the
tool holder and keep the overall length as short as possible.

I was thinking about doing this a while back and I'm now beginning to
remember some the issues I faced back then. I may have come to the
conclusion that the outrunner was not ideal. I need to think about this
some more. I think my last plan was for a backyard version of a Tormach
speeder:
http://www.tormach.com/product_pcnc_acc_speeder.html 

Thanks for the replies.
-- 
Kirk Wallace
http://www.wallacecompany.com/machine_shop/
http://www.wallacecompany.com/E45/index.html
California, USA


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Re: [Emc-users] Outrunners

2012-02-22 Thread James Louis
You might want to check out this site:

http://www.logicnc.com/home.html

They have a parallel port to rc servo converter so LinuxCNC can control an 
outrunner spindle speed.
Cheers,
Jim

-Original Message-
From: Erik Friesen [mailto:e...@aercon.net]
Sent: Wednesday, February 22, 2012 3:19 PM
To: Enhanced Machine Controller (EMC)
Subject: Re: [Emc-users] Outrunners

You could take a look at the marine applications (inrunners), there are
some water cooled.  What will your supply be?  You'll want to decide what
rpm you want to run, as the higher kv, the lower the torque.  Are you going
to belt drive, or direct drive some way?

On Wed, Feb 22, 2012 at 3:58 PM, Claude Froidevaux men...@bluewin.chwrote:

 Le 22.02.2012 21:48, Kirk Wallace a écrit :
  I want to mount an outrunner (or other) to a NMTB40 tool holder to try
  some circuit board routing. I like the outrunner form because it looks
  like the motors seem shorter for the same power. I haven't flown model
  planes for over twenty years so I've lost my feel for sizes and
  capacities. Does anyone have any experience with outrunners for milling
  applications? I'm looking at getting a cheap motor to experiment with
  then build on the experience, so the motor will need to be in the
  disposable price range.

 for PCB routing, inrunner will be better, as you need as much speed as
 possible (40k to 100k rpm). I do some trials by the past with a cheap
 inrunner, abd even without load the temperature rise was too quick to
 allow any real use. I was strongly suspecting the VFD, as cheap as the
 motor... but I never spend more time on it, I got a 24'000 rpm spindle
 that is OK (but way too slow to make fast routing)

 I'm right now waiting for a chinese spindle than must reach 60'000 rpm,
 will see, this shall give a big up to ma PCB routing speed.




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Re: [Emc-users] Outrunners

2012-02-22 Thread Kirk Wallace
On Wed, 2012-02-22 at 16:02 -0600, James Louis wrote:
 You might want to check out this site:
 
 http://www.logicnc.com/home.html
 
 They have a parallel port to rc servo converter so LinuxCNC can control an 
 outrunner spindle speed.
 Cheers,
 Jim

This is what I've done with RC so far:
http://wiki.linuxcnc.org/cgi-bin/wiki.pl?RC_Servo_Test 

Probably good enough for spindle control.
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http://www.wallacecompany.com/machine_shop/
http://www.wallacecompany.com/E45/index.html
California, USA


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Re: [Emc-users] Outrunners

2012-02-22 Thread Eric Keller
On Wed, Feb 22, 2012 at 4:34 PM, andy pugh bodge...@gmail.com wrote:


 Bear in mind that cooling might be inadequate without a huge propellor
 on the front, so expect to derate.

 RC cars use inrunners with heat sinks, so air must not be an absolute
requirement.  Probably a good idea though
Eric
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