FIGUERA'S AETHER MAGNETIC FIELDS LINEAR PUMP, REVIVED

[Ufopolitics]

RELATED TO RECOMMENDED BATCH METHOD TO MARK AND PUNCH ALL 32 COMMUTATOR ELEMENTS FOR DRILLING THE HOLES

Hello All,

Ok, this BATCH (All together at once) Marking Method is designed in order that you make holes on each Commutator Copper Bar, as PRECISELY AS POSSIBLE.

On above image I do NOT have ALL 32 Elements, simply because of Page Room...as I wanted to have a decent size so details on markings could be seen clearly...

HOWEVER,  IT IS UNDERSTOOD THAT ALL 32 -LOOSE- ELEMENTS MUST BE TOGETHER, ALIGNED AND CLAMPED LINEARLY ALL TOGETHER.

The way I will Clamp all these 32 elements is with the help of ANGULAR STEEL OR ALUMINUM BARS AT EACH UPPER AND LOWER ENDS.
As ALSO COMPRESSING THEM ALL TOGETHER, BEFORE MARKING THEM.
SET ALL COMM BARS ON TOP OF A VERY FINE AND FLAT SURFACE.

FIRST, I will need to Mark each Commutator Bar CENTER LINE (So, if I have 6X6 mm Square Bars, this CENTER LINE would be dividing 6, or Line would be at 3 mm.
Second I will CLAMP ALL BARS, FLAT...To then Mark HORIZONTAL ALIGNMENT LINES.
On the LEFT of this Image I have set an already Drilled Commutator Bar, serving as the GUIDE to run the RULER to Mark ALL 32 Bars HORIZONTAL Lines.

Or JUST MARKING the FIRST and LAST BAR, (Three (3) Horizontal Markings) then running the ruler between those TWO POINTS (First & Last)

Finally, on the INTERSECTION OF EACH LINES, I start making ALL the PUNCHING MARKS...

And this is it...

Now, according to your Bench Drill capabilities...you could Drill them ALL Together Clamped...
Or One by One...

Remember that the FEMALE THREADED HOLE MUST BE SMALLER than the PASSING THROUGH BOLTS on the other TWO HOLES that mount Bars to POM Plate.

CLAMPING & SOLDERING OF ALL FOUR (4) DOUBLE ELEMENTS-BARS, IS DONE AFTER, WE FINISH DRILLING AND THREADING ALL 32 LOOSE COMPONENTS.

Then the Aluminum Plate to mount all Copper Bars, to CUT with LATHE-RECTIFY also needs to be marked the CIRCLES (with Compass) where these Holes were LINEARLY MARKED and Drilled.

POM or Polycarbonate Plates ALSO needs to be MARKED with a COMPASS once they are already cut as RINGS.

Regards

Ufopolitics

[kampen]

Subject Ref.: Brush-holder Vertical1-Torsion Spring type

@ All. Hello dear friend Ufopolitics, 

Attached is the latest 3D rendering of the brush holder assembly based directly on my current design.

This version illustrates the vertical torsion spring concept, where the spring is mounted around a vertical slotted pin and applies pressure to the rear of the carbon brush. 

The spring operates perpendicular to the brush travel path, allowing for a very compact assembly while maintaining constant brush pressure.

The rendering also includes an exploded view, dimensional references, fastener details, and spring geometry for easier fabrication and assembly.

The objective is to clearly define the brush mechanism before integrating it into the complete machine assembly.

Comments and suggestions are welcome.

Regards, Alex (user kampen)

[kampen]

[kampen]

Reply to Message # 845 Linear Alignment to Mark PUNCH 32 Elements.

This new information from Ufopolitics is important because it explains how to achieve hole-position consistency across all commutator elements before assembly.

What Ufopolitics is proposing
Instead of marking and drilling each copper bar individually:

• Cut all copper elements first.
• Keep all elements loose and separate.
• Align all 32 elements in a straight line.
• Clamp them tightly together against straight angle bars.
• Establish a common centerline.
• Mark the horizontal hole locations across the entire batch.
• Center-punch all intersections.
• Drill and tap afterward.

The objective is to ensure that every hole location is referenced from the same datum lines, reducing cumulative positioning errors.
Advantages of this method

• All PCB mounting holes end up at the same height.
• All POM mounting holes end up aligned.
• Female-thread PCB holes remain consistent.
• Double elements can be created later from already-matched parts.
• The finished circular commutator will have better concentricity.

One correction for the current design
Your latest commutator specification is:

• 24 single elements
• 4 double elements

This equals:

• 28 physical copper elements

However, Ufopolitics' original drilling method was written when the design still used 32 separate copper bars.

For the current design, the procedure should be modified to:
Updated Batch Layout
Before assembly:

• Align and clamp 28 physical copper pieces.
• 24 single bars (6 × 6 × 20 mm)
• 4 bars that will later become double elements

or alternatively:

• Drill and tap all 32 individual 6 mm bars
• Then solder/braze four pairs into the final 13 mm double elements

The second approach is actually closer to Ufopolitics' original instruction because the double elements are created after drilling and threading.
Recommended manufacturing sequence

• Cut thirty-two 6 × 6 × 20 mm copper bars.
• Align and clamp all 32 bars linearly.
• Mark centerlines.
• Mark horizontal drilling locations.
• Center punch.
• Drill.
• Tap PCB mounting holes.
• Create four double elements:
  
  • 6 mm bar
  • 1 mm copper filler
  • 6 mm bar
• Solder/braze into 13 mm assemblies.
• Machine and square the completed double elements.
• Assemble the commutator ring.

This sequence produces the highest positional accuracy and matches Ufopolitics' Message #845 much more closely than drilling elements individually after ring assembly.

Regards, Alex 

[Ufopolitics]

Hello dear friend @kampen ,

Thank you so much for all your detailed description plus all your SO REALISTIC RENDERINGS!!

Impressive work!!

There is just one minor detail, referring to the Rotor Brushes:

The Torsion Spring PIN + NUT plays a Two (2) Role here:

• Support the Spring Tension to Brush.
• Also serves as the Fastener to
• Mount and tighten Brush Housing to
• Rotor Plates (upper level for Positive & lower level for Negative)

Therefore, this Spring Pin is thinner on top, and have a Wider Thread at lower section.
In order that the Nut could be screwed and tighten that side of Brush Housing to Rotor Plate.

See attached Hand drawings below:

I am not at my PC now...please, pardon my lousy hand sketch, I will make a better drawing later on.

Final point to correct, is that Spring Pin is also a Bolt-Nut that secures Brush Housing to Rotor Plate.

Therefore, Brush Housing is ATTACHED at TWO POINTS on EACH SIDE of Housing to Rotor Plates.

Regards

Ufopolitics