Three Phase DC Brushless Motor

thingiverse

Want an educational brushless motor? Check this out! The rotor uses flat magnets for increased flux, but it's not exactly 1 angstrom away from the stator. Watch my video of a single commutation state here. All parts can be printed without supports. Here's how to make it: 1. Materials: 12x 0.5"x1/16" rare earth magnets, 2x 0.625"OD and 0.25"ID bearings (or print your own), transformer winding wire, and be prepared to patiently wind the stator. 2. Print these parts: stator, stator_top, stator_bottom, rotor, and two shafts with higher infill percentage. 3. Assemble the motor: Wind the stator using the A/B/C markings and CW/CC directions. Each stator arm should have about 300 turns. Solder A-CC, B-CW, and C-CC together. Insert bearings into top and bottom parts, and place magnets in rotor. Slide shafts into the rotor, aligning flat sides with nubs on the stator. 4. To commutate the motor through its six states, apply V+ to one letter and GND to another (e.g., AB means A is at V+ and B is at ground). Faster commutation speeds will make the motor spin faster, but start slow to avoid issues with the rotor. The mounting holes on end caps are 4-40 tapped.