Build your own DC Motor

[Beshires1]

Visit my website to see how I built a large DC Motor from scratch.
http://sites.google.com/site/diydcmotors/ Comments and useful Ideas are welcome

 

[fechter]

That's cool. How did you wind the coils so neatly?

I can imagine you might have a problem with the coils flying off at high speed.

It may work better with iron in the middle of the coils.

Most motors also have 'teeth' on the armature poles that cover over part of the coils so there is only a small gap between teeth. Any teeth or iron inside the coils needs to be laminated or otherwise electrically non conducting. Your steel shot/epoxy mix may be good.

Now think about the next step which would be to make a brushless version. :wink:

 

[Link]

I'd think a brushless would be even easier to make than a brushie, since you don't have to make a commutator. :wink:

Now make one that runs 1.2 jigawatts.

 

[Beshires1]

That's cool. How did you wind the coils so neatly?

I can imagine you might have a problem with the coils flying off at high speed.

It may work better with iron in the middle of the coils.

Most motors also have 'teeth' on the armature poles that cover over part of the coils so there is only a small gap between teeth. Any teeth or iron inside the coils needs to be laminated or otherwise electrically non conducting. Your steel shot/epoxy mix may be good.

Now think about the next step which would be to make a brushless version. :wink:

The coils were wound on a home made hand winder. You can google and find several easy to build versions. One key to keeping them neat is to notch the forms so they can be tied securely before removing the coils. I will add pictures to my "coils and Formers" page. The small gap in the teeth of a rotor"s lamination is so you can get the magnet wire into the wire slot or coil pocket. My method of using the Goop Glue and Sand Blasting Media (steel Shot), is different, but it does offer a alternative to the conventional lamination used in most motors. I can wind larger coils that will increase the rotors diameter 4" or more, this is imposable with the conventional lam rotors. Also Each of my coils have two screws securely holding them in place. I also use nylon ratchet strap belting as banding to further secure the coils from leaving the rotor. As for the Brushless version , I'm already thinking about it.