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Old Sep 05, 2005, 03:10 PM
It's a spiderweb of knit lines
Souderton Pa. USA
Joined Mar 2002
2,651 Posts
Molded Brushless Micro Motor

Hi All,
I've finally found the time to test mold a motor. I still need to make the front bearing carrier so the rotor is just in for show, no performance measurements yet. Here's some pictures.
Mike
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Old Sep 05, 2005, 03:31 PM
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United Kingdom, England, Surrey
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Amazing work. What type of bearings are you using in such a small motor?

Joe
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Old Sep 05, 2005, 03:37 PM
It's a spiderweb of knit lines
Souderton Pa. USA
Joined Mar 2002
2,651 Posts
Hi Joe,
There are many bearing options available to me. I could do ball bearings all around but it isn't really cost or weight effective. Oil impreginated bronze is best (my opinion) brass is next choice. This mold was made for brass so that's what this will get.
Mike
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Old Sep 05, 2005, 03:42 PM
What goes up must come down..
Canada, QC, Saint-Laurent
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Way to go Mike good show!
Please give us more info when you can interesting project!
Roger
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Old Sep 05, 2005, 06:08 PM
Team30 Micro EDF
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Adelaide, Australia
Joined Apr 2004
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What have you used as the laminate around the coil there Mike?
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Old Sep 05, 2005, 07:13 PM
What goes up must come down..
Canada, QC, Saint-Laurent
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The lenght of it...? If you could move them more to the front?
just an idea here since we do not have a full pic...
Roger
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Old Sep 05, 2005, 07:26 PM
It's a spiderweb of knit lines
Souderton Pa. USA
Joined Mar 2002
2,651 Posts
Hi Guys,
This one has ring laminations unlike previous versions I have made. I had to grind them to size and they are shorted on the outside, inside is good. I'll have to wait till I run it to see how good it works. If the shorting on the outside is a problem it can be sanded to eliminate the problem. There are better ring materials and other ways besides rings but performance costs! This is what I can afford, for now.
Length on the next one I make will be shorter, I had to "pull" the stack back a little cause I skimped on the insulation and a phase was shorting to the stack. As it is it withstands 500 VAC Hi-pot test. Also the circuit board is about 1.5mm too far back. I hope to get it down to 7 x 14 mm.
Mike
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Last edited by mcross; Sep 05, 2005 at 07:36 PM.
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Old Sep 05, 2005, 08:08 PM
What goes up must come down..
Canada, QC, Saint-Laurent
Joined Jan 2002
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This one has ring laminations unlike previous versions I have made. I had to grind them to size and they are shorted on the outside, inside is good.

Mike, take care, you are reinventing the wheel for crying sick!
good luck with the sanding to get this one out! tolerances goes with patience...
Roger and out
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Old Sep 05, 2005, 10:05 PM
It's a spiderweb of knit lines
Souderton Pa. USA
Joined Mar 2002
2,651 Posts
Hi Roger,
Sanding isn't really that hard at all, it's just to remove the smear from not having the correct grinding wheel. I probably won't even need to do it, the flux is very well contained within the stack, only a very slight attraction to metal outside the motor.
Mike
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Old Sep 05, 2005, 11:21 PM
What goes up must come down..
Canada, QC, Saint-Laurent
Joined Jan 2002
1,724 Posts
Mike,
maybe I am all wrong, I know it's very hard to keep all things all into a center to center where gaps are playing a major role. wish you good luck with all my hearth.
sheez, I need my glasses, you make me older, i would like to have this kind of enthouasiasm once more!
Very nice Mike once again.
Roger
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Last edited by rodair; Sep 06, 2005 at 09:55 AM. Reason: typo's
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Old Sep 06, 2005, 12:57 AM
Team30 Micro EDF
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Adelaide, Australia
Joined Apr 2004
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what gauge wire did you use? How many turns?
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Old Sep 06, 2005, 06:26 AM
It's a spiderweb of knit lines
Souderton Pa. USA
Joined Mar 2002
2,651 Posts
This one is a very high KV motor. It's 10 turns of 32. Should draw about 1 amp on a single cell at DF speeds. A motor twice as long works very well DD with a GWS 2510, but will weight twice as much.
Note that this stye of motor is very different from outrunners and slotted motors, it turns way faster for the same number of turns.
Mike
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Old Sep 06, 2005, 06:36 AM
Team30 Micro EDF
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Adelaide, Australia
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cool.

I'll be trying my hand at this shortly - just gotta get my workshop refit completed so I can get into all my projects that have been shelved during this time.
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Old Sep 06, 2005, 09:23 AM
TheyreComingToTakeMeAway!
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USA, ID, Coeur D'Alene
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sounds like a mini fiago it'll be sweet. micro ducted fans would sound really cool at that scale

Derrik
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Old Sep 06, 2005, 09:35 PM
It's a spiderweb of knit lines
Souderton Pa. USA
Joined Mar 2002
2,651 Posts
Front bearing holder picture.
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