I designed and 3D printed a brushless DC (BLDC) Motor and control motor using Arduino. In addition to magnets, solenoid winding and Hall effect sensors, all components of the motor are printed with Makerbot Replicator 2. The video shows the finished working motor. This instructable is provided as pdf along with cad files and motor control programs. Arduino\'s motor control program: use the file, review, change the design for free, or do whatever you want with it! This project requires 3D printers, arduino microcontrollers, and basic electronic tools like multimeter, Oscilloscope, power supply, and electrical components. Complete list of parts and tools I use. Table 1 shows the cost of manufacturing the motor. Electrical components such as resistors and capacitors are not included because the cost is negligible relative to the total cost of the motor. Excluding Arduino micro-controllers and batteries, the total cost of manufacturing the motor is $27. 71. It should be pointed out that reducing costs is not the top priority. optimization can reduce production costs. Based on the principle that the motor should be easy to use easily accessible parts to construct, the design specifications of the DC motor are established, and should provide the kind similar to the quality performance of many commercial DC motors, small electric fans. The motor is designed to be 3-phase, 4- Polar DC motor with 4- The N52 nd magnet on the rotor and the 3 wire wound solenoid attached to the stator. Because of the increased efficiency, the number of mechanical parts is reduced, and the friction is reduced, the brushless design is selected. The N52 magnet is chosen for its strength, price and ease of access. In the \"bldc motor control\" section, Brushless motor control will be discussed further. Table 2 shows the comparison between the DC motor and the Brush Motor. Solenoid in 8- 12 V, controlled by an electrical switch circuit. The Hall sensor will provide location information about when the circuit will be swapped. The following equations are used to estimate the performance of the motor, thus creating the initial motor design. If you want to see these equations, take a look at the pdf linked in the intro and they get messed up. The force between the two magnets at A certain distance can be roughly approximate with the following equation: F = BmAmBsAs/4g2, where B is the magnetic field density on the surface of the magnet and A is the area of the magnet, g is the distance between two magnets. Bs, the magnetic field of the solenoid is given by: B = NIl, where I is the current, N is the number of packages, and l is the length of the solenoid. In the motor, the maximum torque is estimated to be: t = 2 frwhere r is the radius and the selection is 25mm. Combined with these equations, a linear expression of the output torque associated with the input current of a given solenoid geometry can be obtained. F = 2rbmamasn4g2li the torque constant required to select is 40 m- Nm/A based on desired performance relative to other available motors [2]. The electronic control circuit is required for the motor control of the BLDC. To rotate the BLDC motor, depending on the position of the rotor, the winding must be powered on in the order defined. The rotor position is detected using the hall sensor embedded in the stator. Figure 3 shows a schematic diagram of the BLDC motor control scheme. The Hall sensor is embedded in the stator with three motor windings, providing a digital output corresponding to whether the Arctic or Antarctic is closest to the sensor. Based on this digital output, the micro-controller provides the phase sequence for the motor driver, thus supplying power to the corresponding winding. Each phase change sequence column has a winding powered on to positive voltage, a winding powered on to negative voltage, and a winding powered on to negative voltage. The phase change sequence consists of six steps that correlate the hall sensor output with the output of the winding that should be powered on. Table 3 below gives an example of a clockwise rotation. The final design consists of 4 different parts; Bottom housing, rotor, top housing and solenoid as shown in Figure 4 below. Figure 4: (a) Bottom shell (b)Rotor (c )Solenoid (d) Assembly motor (e)Top assembly. All parts are displayed in the direction they are printed. The bottom enclosure, as shown in Figure 4 (a) The bottom cover of the motor. Rotor, as shown in Figure 4 (b) , Contains 8 magnets, 4 for driving the motor, and 4 for providing position data to the Hall sensor. As shown in figure 4, the rotor slides to the bottom shell of the sliding bearing style (d). The shell at the top, as shown in Figure 4 (e) , Mounted on the rotor and connected to the bottom to close the motor. The top housing contains 3 hall position sensors, as well as a triangular cut-out that allows the screw tube to snap into the housing. Solenoid as shown in Figure 4 (c) , Place triangles in the center of them to allow them to align with the holes in the top housing, which themselves align vertically with the rotor magnet. All the parts described earlier are printed on Makerbot Replicator 2. Parts can be printed at the same time, and various printing parameters are likely to produce satisfactory results. The final product is printed in transparent PLA plastic, with a filling amount of 20% and a filling amount of 0. 20mm floor height. Through repeated trials, it is found that parts that are connected together without sliding, such as the top and bottom shells, should be printed at 0. Add 25mm to all sides, while parts for free sliding, such as rotors, should be printed at 0. 4mm space around. The magnet and Hall effect sensor print to the right bottom of the top of the gap by designing the right internal void in the right place, pause printing and insert the device, be inserted into the assembly, and then continue printing. The appropriate pause height is given in Table 4 below. The 3D print piece can be removed from the Makerbot and can be assembled together after removing the excess plastic from the raft. These parts should be put together smoothly without much effort. Solenoid solenoid need the last solenoidprocessing. Each solenoid is wrapped about 400 times with a 26gw magnet line. This process can be accelerated by turning the solenoid on the drill bit. Make sure that each solenoid is packed in the same direction so that the resulting solenoid has the same polarity. Once the solenoid is ready, they should be snapped into the shell at the top. Strong glue can be used here to strengthen the connection. The circuit elements should be connected together according to the following schematic diagram. The VCC of the L6234 motor driver can be anywhere from 7 v to 42 V, but I recommend running the motor without being higher than 12ish V. The program written by Arduino to control the phase change order can be found in the program, which is adapted according to this manual. The future improvement of the motor can be divided into four categories; Mechanical optimization, efficiency improvement, control improvement and application. The first step in any future work should be to test the torque Speed and efficiency of current motor. The control of the motor can be achieved using a hardware method rather than a software method, which will greatly reduce the cost and scale of the implementation. Here is a brief description of how this can be achieved- There are many areas where the mechanical design of the motor can be optimized. The solenoid can be simply inserted into the main body of the motor. The size of the motor can be significantly reduced. The size of the position magnet can be greatly reduced to reduce the torque of the rotor. The motor design may be parameterized and printed in a variety of different sizes. The efficiency of the motor can be optimized by checking the torque Speed characteristic within the range of applied voltage. If the fully optimized 3D printing motor can be parameterized and printed in a variety of different sizes and ratings, the application range will be very wide. This is my evernote notebook with a lot of articles and links I studied while doing this project. Important sources[1] Basic principle of DC motor- Padmaraja Yedamale- Understand DC motor
