{"id":10463,"date":"2015-10-14T14:59:51","date_gmt":"2015-10-14T21:59:51","guid":{"rendered":"http:\/\/cafe.foundation\/blog\/?p=10463"},"modified":"2015-10-14T14:59:51","modified_gmt":"2015-10-14T21:59:51","slug":"eas-ix-david-calleys-innovative-design-and-use-of-electric-motors","status":"publish","type":"post","link":"http:\/\/cafe.foundation\/blog\/eas-ix-david-calleys-innovative-design-and-use-of-electric-motors\/","title":{"rendered":"EAS IX: David Calley&#8217;s Innovative Design and Use of Electric Motors"},"content":{"rendered":"<p>David Calley is \u00a0member of the CAFE Foundation Advisory Board, with a great deal of technical expertise to offer.\u00a0 His small wind turbine sold over 150,000 units.\u00a0 His patented design for the TrailerTail\u00ae increases fuel economy on semi-trucks and trailers by 5.4 percent at 65 miles per hour, according to SAE tests.\u00a0 <a href=\"http:\/\/cafe.foundation\/blog\/eas-viii-high-torque-efficiency-powerful-motors\/\">Last year at EAS VIII<\/a>, he showed the potential for small motors with incredible torque that could power Sky Taxis.<\/p>\n<p>At this year\u2019s EAS IX he described, in depth, the type of motor design he has been developing to power things like his three-wheel electric\/pedal-powered commuter vehicle and landing-gear wheels on Sky Taxis and even rocket fuel pumps.<\/p>\n<p>He asked the not-too-rhetorical questions, \u201cHow high can electric motor power go?\u201d and \u201cWhere do these forces come from?\u201d\u00a0 His answers took attendees on a high-level look at electromagnetic and permanent magnet (PM) materials theories.<\/p>\n<div id=\"attachment_10466\" style=\"width: 538px\" class=\"wp-caption aligncenter\"><a href=\"http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/EAS-IX-David-Calley-Rocket-Pump.jpg\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-10466\" class=\"size-large wp-image-10466\" src=\"http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/EAS-IX-David-Calley-Rocket-Pump-528x396.jpg\" alt=\"Lithium-battery powered turbo pump was more efficient in delivering rocket fuel\" width=\"528\" height=\"396\" srcset=\"http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/EAS-IX-David-Calley-Rocket-Pump-528x396.jpg 528w, http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/EAS-IX-David-Calley-Rocket-Pump-300x225.jpg 300w, http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/EAS-IX-David-Calley-Rocket-Pump.jpg 1095w\" sizes=\"auto, (max-width: 528px) 100vw, 528px\" \/><\/a><p id=\"caption-attachment-10466\" class=\"wp-caption-text\">Lithium-battery powered turbo pump was more efficient in delivering rocket fuel<\/p><\/div>\n<p>Electric motors rely on interactions between fields to produce power.\u00a0 \u201cFields\u201d in this case are an electric field viewed from a different angle, an everyday example of special relativity, according to David.<\/p>\n<p>His brief explanation, paraphased lightly here, is that in fields with motion relative to a conductor such as copper, the moving charge sees length contraction due to apparent velocity changes between free electrons versus fixed positive metal ions, causing a force due to the charge.\u00a0 To the stationary observer it is what we call a magnetic field.\u00a0 This caused a mild discomfiture to your editor until he sorted out the idea that what we see as a motor turning a few hundred or thousand revolutions per minute is actually being motivated by electrons flowing at the speed of light.\u00a0 All the ideas Einstein expressed as special relativity become very real along the moving and stationary parts of the motor.<\/p>\n<div id=\"attachment_10468\" style=\"width: 538px\" class=\"wp-caption aligncenter\"><a href=\"http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/eas-IX-David-Calley-Tesla-Motor.jpg\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-10468\" class=\"size-large wp-image-10468\" src=\"http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/eas-IX-David-Calley-Tesla-Motor-528x396.jpg\" alt=\"David Calley traced a direct descendancy from Tesla's motor to his current designs\" width=\"528\" height=\"396\" srcset=\"http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/eas-IX-David-Calley-Tesla-Motor-528x396.jpg 528w, http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/eas-IX-David-Calley-Tesla-Motor-300x225.jpg 300w, http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/eas-IX-David-Calley-Tesla-Motor.jpg 1095w\" sizes=\"auto, (max-width: 528px) 100vw, 528px\" \/><\/a><p id=\"caption-attachment-10468\" class=\"wp-caption-text\">David Calley traced an intellectual history from Tesla&#8217;s motor to his current hoped-for designs<\/p><\/div>\n<p><a href=\"http:\/\/newt.phys.unsw.edu.au\/einsteinlight\/jw\/module2_FEB.htm\">See here for a better explanation<\/a> of special relativity as it functions in motors.<\/p>\n<p>This diversion into Einsteinian physics leads to an attempt to define, or at least understand, what the term Tesla means as applied to magnetic force.\u00a0 Rare earth neodymium magnets, for instance, rate at about 1.3 Tesla (T), while iron saturates at around 2 Tesla.\u00a0 MRI (magnetic resonance imaging) machines range from 1.5 \u2013 3 T for hospital and clinic models to up to 8 for research machines.\u00a0 Super conduction fields hit 35 to 40 T, and explosive fields in laboratories have reached 2,800 T.\u00a0 Taking the idea even further out, magnetars, a form of neutron star, have Tesla values in the trillions.\u00a0 By contrast, a typical refrigerator magnet registers a puny 5 milli-Tesla, but enough to hold your kid\u2019s artwork for your gaze.<\/p>\n<p>Magnetars are a very dense neutron star about 12 miles in diameter with a greater mass than our sun, a thimble full of magnetar weighing about 100 million tons.<\/p>\n<p>According to <a href=\"http:\/\/www.space.com\/30263-paul-sutter-on-why-magnetars-are-scary.html\">Space.com<\/a>, \u201cGet too close to one (say, within 1,000 kilometers, or about 600 miles), and the magnetic fields are strong enough to upset not just your bioelectricity \u2014 rendering your nerve impulses hilariously useless \u2014 but your very molecular structure.\u00a0In a magnetar&#8217;s field, you just kind of \u2026 dissolve.\u201d\u00a0 The magnetism is too extraordinary for practical use, in other words.<\/p>\n<p><iframe loading=\"lazy\" title=\"Tesla&#039;s Induction Motor: Functional museum replica\" width=\"500\" height=\"375\" src=\"https:\/\/www.youtube.com\/embed\/hAn1SDcyF2E?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe><\/p>\n<p>Trying to develop a powerful, light motor requires intelligent materials selection and arranging these materials into a topology that gets the most from them.\u00a0 David ran through a shopping list of magnetic materials and how they might act in a moving field.<\/p>\n<p>A motor developer has a full kit from which to select, with ferromagnetic materials attracted to magnetic fields, diamagnetic components opposed to an applied field, and most contrary of all, antiferromagnetic objects in which magnetic domains cancel one another, adjacent ions pointing away from each other and cancelling any magnetic attraction to the material.\u00a0 Paramagnetic materials take on the magnetic fields around them, but lose it when moved away from the field.\u00a0 A reasonable overview of these materials and their properties can be found in this abstract.<\/p>\n<div id=\"attachment_10467\" style=\"width: 538px\" class=\"wp-caption aligncenter\"><a href=\"http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/EAS-IX-David-Calley-Disk-Loading.jpg\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-10467\" class=\"size-large wp-image-10467\" src=\"http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/EAS-IX-David-Calley-Disk-Loading-528x396.jpg\" alt=\"Light disk loading requires large blades, thus high torque to turn them\" width=\"528\" height=\"396\" srcset=\"http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/EAS-IX-David-Calley-Disk-Loading-528x396.jpg 528w, http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/EAS-IX-David-Calley-Disk-Loading-300x225.jpg 300w, http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/EAS-IX-David-Calley-Disk-Loading.jpg 1095w\" sizes=\"auto, (max-width: 528px) 100vw, 528px\" \/><\/a><p id=\"caption-attachment-10467\" class=\"wp-caption-text\">Light disk loading requires large blades, thus high torque to turn them, generate lift<\/p><\/div>\n<p>One type of paramagnetic material, if your editor is making the right association, <a href=\"http:\/\/www.ipmd.net\/shop\/Powder_based_magnets_and_their_applications\">64 MgO (magnesium oxide) is a soft magnetic material <\/a>through which magnetic fields travel more easily than through other, harder materials.\u00a0 Combined with specially-selected composite materials, these types of compounds offer specific properties that lead to high-output, high-torque motors capable of turning large helicopter blades at low speeds with high lift capabilities.\u00a0 The poor man\u2019s (or woman\u2019s) VR-22 Osprey could be an outcome here.\u00a0 The same technology applied to aircraft-sized wheel motors could accelerate a Sky Taxi to takeoff velocity quickly and efficiently.<\/p>\n<div id=\"attachment_10465\" style=\"width: 538px\" class=\"wp-caption aligncenter\"><a href=\"http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/EAS-IX-david-calley-2.jpg\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-10465\" class=\"size-large wp-image-10465\" src=\"http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/EAS-IX-david-calley-2-528x396.jpg\" alt=\"Axial Transverse Flux Motor (ATFM) combines high torque and potentially high speeds in a compact, light package\" width=\"528\" height=\"396\" srcset=\"http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/EAS-IX-david-calley-2-528x396.jpg 528w, http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/EAS-IX-david-calley-2-300x225.jpg 300w, http:\/\/cafe.foundation\/blog\/wp-content\/uploads\/2015\/10\/EAS-IX-david-calley-2.jpg 1095w\" sizes=\"auto, (max-width: 528px) 100vw, 528px\" \/><\/a><p id=\"caption-attachment-10465\" class=\"wp-caption-text\">Axial Transverse Flux Motor (ATFM) combines high torque and potentially high speeds in a compact, light package<\/p><\/div>\n<p>David\u2019s new axial transverse flux motor (ATFM) might overcome the constraints that axial or transverse flux motors have in themselves.\u00a0 His new topology and choice of materials was first applied on a robot assembly line, where the torque necessary for successful operation needed to be packaged in a motor 1\/100<sup>th<\/sup> the size of the original unit.\u00a0 Compact combinations such as David Calley\u2019s motor might combine the high starting torque of axial-flux machines with the high speed capabilities of transverse flux units.<\/p>\n<p><iframe loading=\"lazy\" title=\"Planet Rider outline in 120 seconds\" width=\"500\" height=\"281\" src=\"https:\/\/www.youtube.com\/embed\/v_IMVROXQ8o?start=25&#038;feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe><\/p>\n<p>Nikolai Tesla designed a motor with some of these characteristics over 100 years ago.\u00a0 We may have forgotten its origins, but David Calley is applying those lessons to his hybrid pedal electric bike drive application.\u00a0 We hope to see this and other ideas coming to fruition soon.<\/p>\n<div id=\"facebook_like\"><iframe src=\"http:\/\/www.facebook.com\/plugins\/like.php?href=http%3A%2F%2Fcafe.foundation%2Fblog%2Feas-ix-david-calleys-innovative-design-and-use-of-electric-motors%2F&amp;layout=standard&amp;show_faces=true&amp;width=500&amp;action=like&amp;font=segoe+ui&amp;colorscheme=light&amp;height=80\" scrolling=\"no\" frameborder=\"0\" style=\"border:none; overflow:hidden; width:500px; height:80px;\" allowTransparency=\"true\"><\/iframe><\/div>","protected":false},"excerpt":{"rendered":"<p>David Calley is \u00a0member of the CAFE Foundation Advisory Board, with a great deal of technical expertise to offer.\u00a0 His small wind turbine sold over 150,000 units.\u00a0 His patented design for the TrailerTail\u00ae increases fuel economy on semi-trucks and trailers by 5.4 percent at 65 miles per hour, according to SAE tests.\u00a0 Last year at [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"footnotes":""},"categories":[6680,6660,15,3,14],"tags":[6793,6791,5054,1990,6150,3595,6794,6790,5049,6792,5141,4101],"class_list":["post-10463","post","type-post","status-publish","format-standard","category-electric-aircraft-components","category-electric-aircraft-materials","category-electric_powerplants","category-gfc","category-sustainable_ga","tag-acrylichomopolar-motor","tag-axial-flux-motor","tag-axial-transverse-flux-motor","tag-david-calley","tag-eas-ix","tag-electric-motors","tag-helicopter-disk-loading","tag-nikolai-tesla","tag-planet-rider-llc","tag-radial-flux-motor","tag-sky-taxis","tag-wheel-motors"],"yoast_head":"<!-- This site is optimized with the 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