The rotor is designed to work in conjunction with the 12-coil PCB Stator. By utilizing a circular Halbach Array, we eliminate the need for heavy steel back-iron (flux return path), significantly reducing the rotating mass of the turbine assembly. This is critical for low-wind startup and reducing the gyroscopic loads on the personnel lift frame.
- Outer Diameter (OD): 200mm [7.87 in] (matches Stator OD).
- Inner Diameter (ID): 80mm [3.15 in].
- Thickness: 10mm [0.39 in] (including magnet pockets).
- Magnet Active Radius: 70mm [2.76 in] (center of magnet track).
- Pole Count: 10 Poles (5 North, 5 South).
- Array Type: Circular Halbach (90° Transition).
- Magnet Type: N52 Neodymium (NdFeB).
- Magnet Shape: Rectangular blocks or Trapezoidal (preferred for flux density uniformity).
- Dimensions: 25mm x 15mm x 5mm [0.98 x 0.59 x 0.20 in].
- Orientation Strategy:
- Magnets are arranged such that the magnetic flux is intensified on the stator-facing side and nearly cancelled on the rear side.
- Transition magnets (90° orientation) bridge the primary poles.
- Substrate: Carbon Fiber Reinforced Polymer (CFRP) or High-Temperature Carbon-PETG.
- Fabrication: CNC-milled CFRP plate or 3D-printed with 100% infill and annealed.
- Magnet Retention:
- Precision-machined pockets with 0.1mm interference fit.
- Secondary retention via high-strength cyanoacrylate (Loctite 480) or thermally-stable epoxy.
- A 0.5mm CFRP "skin" is bonded over the pockets to prevent magnet ejection at high RPM.
- Flux Density (Bpeak): > 0.6T at the stator winding surface (1.0mm air gap).
- Weight: < 450g [1.0 lb] per rotor unit.
- Max RPM: 2,000 RPM (Safety factor of 3x over design operating RPM).
- Interface: 10mm Stainless Steel shaft.
- Hub: Integrated 6061-T6 Aluminum hub with dual set-screws and keyway.
- Alignment: Precision shims are used to maintain a consistent 1.0mm [40 mil] air gap between the Halbach magnets and the PCB stator surface.
Last updated 2026-06-10.