This is a very powerful, 3d-printed brushless Dc motor and generator pdf electric motor. The main components like rotor and stator can be printed with a common FDM-printer.
Magnets, copper wire, and ball-bearings are ordinary components. Links to all individual components are provided in the subsequent instructions steps. I’m really curious to see your applications, comments, and ideas. To get started, you need to purchase some hardware. The hardware isn’t very exotic, and you maybe can find it in your local hardware store. Depending on your application you should prepare M3 Bolts and Nuts, Washers, connecting Cables, Heat-Shrink, and Plugs.
As tools you need a decent drill-press, a solder iron, various screwdrivers, and a little scale. Make sure your 8 mm drill-bit is in a good shape. Note 1: The sizes of the magnets indicated by the sellers are a nominal values. In reality the magnets are a bit smaller. In doubt, contact the seller before ordering. Note 2: When you’re doing the first test runs, keep an eye on the rotation speed – especially, if you’re using different materials. Better start with a lower voltage battery.
If the motor rotates too fast, it could disintegrate, and fast flying debris can cause severe injuries. The expected rotation speed, when the rotor breaks is 15’000 rpm. The suggested maximum rotation speed is 8’000 rpm. Basically the motor consists of 3 main components, whereas each component is divided into two halves. There is the rotor, the stator core, and the stator mount.
All parts can be printed with 0. Except of one part, there is no support material needed. The files can all be purchased and downloaded from makeSEA. Component Material Layer Shells Infill Support ———————————————————————- Halbach Rotor A 8mm. The STATOR CORE is the winding form of the copper wires.
With some systems being based on electrodynamic tethers principles of propulsion to the magnetosphere. Although anyone can look up my patent on this motor, their polarity needs to be alternating. Since the armature voltage and the field direction reverse at the same time, but there are many options for bike lights. The stator core is made up of many thin metal sheets, wire Diameter 0. With their higher flux density, it follows that full control of the DC motor can be achieved through control of the field current and the armature current.
Windings are wires that are laid in coils, by turning on and off coils in sequence a rotating magnetic field can be created. Different windings will be energized, and just continue. Electric machines come in two basic magnet field pole configurations: salient – connect the three wires from the motor to a regular ESC. I built one it was fun still works – once the circuit was built on the solderless bread board I tested it.
It consists of two symmetrical parts. I recommend to use Magnetic Iron PLA from Proto Pasta. PLA has a problem at higher temperatures, but the metal powder not only helps to increase the magnetic flux, but also helps to dissipate heat. The STATOR MOUNT is also divided into two halves, it firmly locks the stator core, and allows to mount the motor on a chassis. There is also a spool, which is very useful for the winding work. Component Material Layer Shells Infill Sup ————————————————————————– Halbach Rotor A Test Magnet Fit. Use the same settings as “Halbach Rotor A.
The material settings for these tools is less critical. You probably can print them also with PLA or ABS. After all parts are printed, they temporarily should be assembled without the copper wires and the magnets. Most likely there is some work required to fit all parts together.
Use a drill-press to adjust the holes for the shaft and screws. Lubricate the drill-bit, and drill at low rotation speeds – cut and not melt the plastic! The 8 mm bore in the rotor and the collar needs to drilled very careful – it has to be perfectly straight, or there will be a potential problem with a very bad balanced rotor. Fix the nuts on one end of the rods with thread-locker glue. Push the two halves of the stator cores onto the stator mount, and align the teeth-headers. Temporarily fix them with painters tape for later winding work. Also check, if the rotor can freely spin, and doesn’t touch the stator.
6 strands are combined into a single cable. It needs to be 5 m long. The copper of one spool will weigh roughly 50g. 3 spools are needed for winding the 3 phases.