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Thread: Brushless DC Motor for High Torque Experiments

  1. #21
    Thanks Gary. That may be a good option. I completed the file for sample motor end/ bearing holders. This is what I will use on mine. It is for 3/4" X 1 5/8" X 7/16" bearings. The inner bolts are 6-32 X 3/4" and the outer holes will be for 1/8" threaded rod to connect both sides. There will be an inch of room on both sides of the stator for wire to stick out. Pictures are included here. You will need to print or have printed (2) bearing holders and (8) legs (4) for each side. My extruder stepper died during the 1st two leg print, but I was able to check compatibility with the stator. It works beautifully. I sent Tom w/ Teslagenx the files if anyone needs them printed.

    Enjoy
    DougIMG_20170708_140158_810.jpgIMG_20170708_140212_014.jpg
    Last edited by DMANN; 07-08-2017 at 11:31 AM. Reason: Teslagenx

  2. #22
    20170809_154454.jpg20170805_055850.jpg This first one is wired for a monopole application and not a BLDC. The magnets on the rotor match the number of stator poles (12).

  3. #23
    The magnetic lock with the 12 magnets = the 12 stators was just too strong. I had the coils wound with 3 sets of 4 in series. It took shorting the coils with two 12V lawn batteries in series to even turn it. So I have decided to offset the number of magnets to stator poles. I am currently printing a 10 magnet rotor. I believe that will allow me to turn it with much less power. I will save the 12 magnet rotor for a generator add-on for later. My busy season with work has picked up so this project is going to be slow-go from here to the end of the year.

  4. #24
    These are a couple of resources for those that are interested for wiring and running a true BLDC motor. http://www.bavaria-direct.co.za/scheme/calculator/
    I did not know that rc had gotten so powerful until I did some research. Here is a powerful esc at a reasonable price. It auto senses so you can use halls or not. https://www.rcsuperstore.com/Traxxas...shoppingengine

  5. #25
    I posted a outrunner stator mold to Thingiverse if anyone may be interested. It uses the Babcock process with #8 steel shot. It can be used in a generator, a monopole motor, or bldc motor design. https://www.thingiverse.com/thing:2954231

    Doug

  6. #26
    Sandwich style bearing hubs added along with wire protector boots to go on slots on 06/26/2018 at 12:43 PM est. Bearing size is 3/4" X 1 5/8" X 7/16". Bolts holes are for 1/4" bolts. You will need to get bolts the length to fit to whatever you are mounting to. The boots are glued to the slots (top and bottom). I am currently working on a sample magnet rotor using a 8" cake pan Pictures are provided at: https://www.thingiverse.com/thing:2954231

    Doug

  7. #27
    Drill jig for 8 in. cake pan added on 06/26/2018 at 4:27 PM est. Use a 1/4" drill bit for holes. Once all holes are drilled you can take a step up drill bit to drill the center hole to 3/4" for the shaft. I'm working on the hubs to be posted next. This is the cake pan that I am using (Wilton Bakeware 8" x 2" Performance Cake Pan, Round) 7 dollars from Walmart

    Doug

    Bearing rotor (cake pan) hubs added at 10:26 PM on 06/26/2018.
    Last edited by DMANN; 06-26-2018 at 07:26 PM. Reason: added rotor hub info

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