Brushless DC Motor

thingiverse

This motor is part of a university project for ENGR 320 at the University of British Columbia Okanagan Campus, where I am a third year mechanical engineering student. The assignment calls for designing and building an electric motor of any type, and I chose to build a brushless DC motor with an in-runner configuration - where the rotor spins inside the stator. This project has consumed a lot of my time and involved extensive printing and reprinting for precise tolerances. Here is a list of materials used and their purposes: Stator Shell (housing) - Made from Red PLA, 0.2mm layer height, with 30% infill End Caps - Same as before, with increased infill to support the bearings and shaft Stator(inner) - Protopasta Magnetic PLA where I wound the 6 coils, split in half due to winding difficulties Rotor - Black ABS, with 50% infill for weight reduction while maintaining strength Shaft - A 5mm stainless steel rod, possibly replaced by aluminum due to its non-magnetic properties Bearings - 5x11x4 RC bearings Windings - Delta configuration using 0.067mm copper enameled motor wire Hardware - 8xM3 cap head screws Magnets - 4x 30x10x4mm neodymium magnets Speed Control - XP Digital Brushless ESC with Axial AR3 controller/module This project is not yet complete, and my knowledge of building motors is limited. However, I'm doing the best I can and hoping it will work out! I hope you guys can enjoy this project and maybe offer some improvements; let me know what you think! UPDATE: The motor has been built, and the split stator windings needed to be sanded slightly to fit snugly into the stator housing. Three holes were drilled in the back cap to feed the wires through, and the motor was wired in a Delta configuration. Hopefully, it works! I will update once tested. UPDATE #2: This motor project turned out to be fantastic! The wire could have been thinner to achieve more windings, but other than that, it performed decently well.