FIGUERA'S AETHER MAGNETIC FIELDS LINEAR PUMP, REVIVED

[kampen]

Engineeering 3-D Rendering to Message # 822

@ All and fellow builders,
Based on Ufopolitics' latest rectangular copper bar commutator concept, I have created a preliminary 3D engineering rendering to help visualize the assembly before moving toward detailed manufacturing drawings.
The model follows the current assumptions:
• Plate OD: 152.4 mm
• Center Bore ID: 66.24 mm
• Copper Inner Radius (Lathe Cut Line): 38.0 mm
• Copper Outer Radius: 65.0 mm
• Virtual Timing Slots: 32
• Physical Copper Elements: 28
• Four Double Elements located at 0°, 90°, 180°, and 270°
• Twenty-Four Single Elements
• Gap Angle Between Elements: 1.2°
Important observations:

• The four Double Elements are clearly visible at the four main axes (12, 3, 6, and 9 o'clock positions). These establish the primary alignment references during assembly.
• The design uses simple rectangular copper bars rather than traditional molded commutator segments. This should dramatically reduce fabrication complexity and cost.
• The copper bars themselves form a substantial heat sink structure while maintaining true air gaps between adjacent elements for cooling and cleaning access.
• The lathe-cut line is preserved so that all elements can be assembled first and then lightly machined to produce a uniform brush-contact radius.
• The concept appears much more practical for replication by ordinary machine shops than a traditional molded mica commutator.

Before proceeding to manufacturing drawings, I believe the following items still need to be finalized:
• Exact copper bar dimensions (width, thickness, length)
• Brush width and brush overlap strategy
• Air-gap specification (0.5 mm, 1.0 mm, or 1.5 mm)
• Fastener size and thread specification
• Top clamping plate geometry
• PCB mounting arrangement
• Final numbering of all commutator positions
My personal impression is that this new commutator architecture may be one of the most replication-friendly designs presented so far. 
It avoids expensive custom copper extrusions, avoids molded commutator manufacturing, and uses readily available materials while preserving the intended timing sequence.
I welcome comments, corrections, and suggestions before moving to a fully dimensioned fabrication drawing package.

Best regards, Alex (user kampen)

[Art Z.]

Hello team and dear Alex,

Everything looks good and simple enough to understand. Only one thing needs attention in details section. The single element needs to be 6x6x20mm and double element needs to be 6x12x20mm plus 1mm.
I understand that the numbers are not final because everyone who builds the commutator will match what brushes and parts are being used. If we make the double element 42mm long it will simply get on the way of POM mounting hole. I'm halfway done with my sequential coils and very soon will concentrate on commutator built.

Regards!!!

[Ufopolitics]

Hello All,
Hello @Art Z. and dear friend @kampen ,

Beautiful rendered images Kampen!!

And,Yes, Art is correct! Great observation there Art!

All Elements must be same lengths.

Also the POM Plates do NOT reach all the way inwards (towards center) to meet commutator elements line (like it shows on rendered images). The POM ends before, leaving the future PCB connecting bolts free, just between Commutator Elements & PCB.

So, yes, I think this commutator build is much easier than ALL previous ones.
There are many other tips to put it together...
Like you can use an inner cylinder to guide-align all elements in a perfectly rounded order.
Before drilling holes to POM or Polycarbonate Plates.

We have MANY ADVANTAGES in these type of Static Commutators versus a Typical commutator build which connects at shaft of motor or generator.

There are many restrictions on a typical comm.
We do not have any restrictions, nor limits, as we can build freely in both directions (OD& ID)
As in Height...

It just depends on our inner components, basically the Brushes assembly, which defines our Inner Diameter to set commutator elements.
Also size of our Rotor Shaft, then from there, it will give us the diameter of Rotor Plates.

Regards

Ufopolitics

[kampen]

Reply to Message # 826

Hello Art Z.,
Thank you for the valuable observation.
I completely agree with your point regarding the dimensions of the commutator elements.

The dimensions shown in my recent rendering were intended only as a conceptual visualization of the architecture and not as final manufacturing dimensions. 

Your comment highlights exactly why the mechanical details must be reviewed before we release a fabrication drawing.
Based on your proposal:
Single Element:
6 mm × 6 mm × 20 mm
Double Element:
6 mm × (12 mm + 1 mm center-gap fill) × 20 mm
This makes much more practical sense from a construction standpoint.
As you correctly pointed out, increasing the element length too much could interfere with the POM mounting holes and reduce the available space needed for mechanical fastening.

Maintaining a compact 20 mm element length should simplify machining, reduce material cost, and improve overall assembly.
Another advantage is that these dimensions are compatible with the concept Ufopolitics described of building the Double Elements from two standard Single Elements plus a copper (or brass) filler strip. 

That means builders only need to stock one copper bar size and can fabricate all elements from the same material.
I also agree that the final dimensions may vary slightly depending on:
• Brush width
• Brush holder design
• Air-gap spacing selected
• Current carrying requirements
• Available copper stock dimensions
Therefore, I suggest that we treat the 6×6×20 mm Single Element as the current baseline reference design until further testing indicates otherwise.

Congratulations on being halfway through the sequential coil assembly. 

It is encouraging to see a physical build progressing. Your practical feedback from the workshop is extremely valuable because it helps convert the concept into a machine-shop-friendly design that others can replicate.

Looking forward to seeing your progress on the commutator construction.

Best regards,
Alex (user kampen)

Remark:
From an engineering standpoint, Art Z. is correct. A 20 mm long copper element is much more realistic for a first prototype than the longer bars shown in the conceptual render, and it keeps the mechanical assembly compact and easier to fabricate.

[kampen]

Subject Ref.: I made a correction to this rendering as written recommend by Art Z.

The rendering has been updated conceptually according to Art Z.'s recommendation:

Based on Art Z.'s excellent observation, I have updated the commutator rendering dimensions to better reflect a practical machine-shop implementation.
Revised Copper Element Dimensions
Single Element (24 Places)

• Width: 6 mm
• Thickness: 6 mm
• Length: 20 mm

Double Element (4 Places)

• Width: 12 mm + 1 mm laminated filler
• Thickness: 6 mm
• Length: 20 mm

The additional 1 mm represents the filled center gap between two standard single elements, following the laminated construction method proposed by Ufopolitics.
Important Correction
The previous rendering showed a double-element length of 42 mm. 
After reviewing Art Z.'s comments, this dimension is not practical because it would interfere with the POM mounting-hole locations and unnecessarily increase the overall size of the assembly.
The revised 20 mm element length provides:

• Better mechanical clearance
• Easier machining
• Lower material cost
• Improved compatibility with the POM support structure
• Simpler replication by builders

Current Design Assumptions

• Plate OD: 152.4 mm
• Center Bore ID: 66.24 mm
• Copper Inner Radius (Lathe Cut Line): 38.0 mm
• Copper Outer Radius: 65.0 mm
• Virtual Timing Slots: 32
• Physical Copper Elements: 28
• Double Elements: 4 located at 0°, 90°, 180°, and 270°
• Single Elements: 24
• Gap Angle Between Physical Elements: 1.2°

Remaining Items To Finalize
Before releasing a fabrication drawing package, I believe we still need to agree on:

• Brush width
• Air-gap spacing (0.5 mm, 1.0 mm, or 1.5 mm)
• Copper-bar stock dimensions
• PCB mounting thread size
• POM plate thickness
• Final brush-holder arrangement

Many thanks to Art Z. for catching this important dimensional issue before the design progresses further.
Also, congratulations on being halfway through the sequential coil assembly. 

It is great to see a physical build moving forward, and your workshop experience is helping transform this concept into a practical and reproducible machine.
Best regards,
Alex (user kampen)
Note:
"The dimensions shown are considered a baseline reference design and may be adjusted slightly to accommodate different brush sizes and available materials."