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Bill Dube wrote:
The issue would be the spline pattern on the sun gear shaft. Is it the same diameter, does it have the same number of spines, and is there enough spline available in front of the flex plate to fit the rotor on? I know the hole in the rotor is a 1" diameter, 10-spline hole.
What would prevent you from just sliding the rotor (with just a round hole) over the splined shaft, and attaching it to the flexplate with a few screws? Splines are expensive to machine.
Balance. Control that and you're golden. Get it off center by a little and...well...I don't know what would happen...but I BET that it wouldn't be good 8*)
I like the idea of using the splines, because that will control the balance, and provide solid trap for all the radial forces driving the system. With the screws, you're depending on them for both radial and axial forces. Not that they can't be sized appropriately, I just don't think they'd be as dependable as the spline.
Finn, while true that the generator should get some cooling air flow, I don't think there is much chance of the magnets coming loose from a decently built unit. The magnets are glued to the inside of a can. The very substantial centrifugal will push them harder into the inside wall. If they can provide robust service to the barking Harleys that certain people have been so fond of the past few years while only spinning at 3000RPM, I think they'd be outstanding performers spinning a 6000 in a Mazda that goes Hmmm...
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