Compared with traditional motors, coreless motors have unique advantages such as low loss, high response speed, and no cogging effect. They shine in the fields of model aircraft, robots, precision instruments, etc. Many technology enthusiasts are curious about coreless motors. Today, I will lead you into the world of coreless motors and teach you how to make your own coreless motor.
Exploring the working principle of coreless motors
The coreless motor operates based on the law of electromagnetic induction, with the stator and rotor structure as the core. It boldly “abandons” the stator core in traditional motors, uses hollow coils as stators, and the rotor is composed of permanent magnets. When current passes through the hollow coil, a magnetic field is generated, which interacts with the magnetic field of the rotor permanent magnet to drive the rotor to rotate. This unique structural design reduces energy loss and improves the efficiency and performance of the motor.
Prepare materials and tools
Making a coreless motor requires preparing materials and tools in advance. Here is a detailed list:
(I) Materials
Enameled wire: The diameter of the enameled wire will affect the power and performance of the motor. You can choose according to your needs and design.
Permanent magnet: High-performance NdFeB permanent magnets are a good choice. Prepare permanent magnets of appropriate shape and size according to the motor size and design requirements.
Insulating materials: Such as insulating tape, insulating paper, etc., used for insulation treatment of the coil to ensure the safety of the motor operation.
Axle: You can choose a metal shaft to ensure sufficient strength and precision to support the rotor and transmit torque.
Brackets and fixing parts: Used to fix the stator and rotor. Common materials include plastic or metal brackets, screws, etc.
(II) Tools
Winding tools: Winding machines or simple winding racks, which are convenient for winding enameled wire into coils.
Welding tools: Electric soldering irons and solder wires are used to connect circuits and fix parts.
Scissors: Cut enameled wires, insulating materials, etc.
Sandpaper: used to remove the paint on both ends of the enameled wire for welding.
Measuring tools: such as vernier calipers and rulers, used to measure the size of the material to ensure production accuracy.
Start making a coreless motor
(I) Make a stator coil
Design the shape and size of the coil: Determine the shape (such as round, rectangular, etc.) and size of the coil according to the design requirements of the motor.
Winding the coil: Fix the enameled wire on the winding mold and start winding the coil. During the winding process, keep the coil tight and neat. The number of turns depends on the power and voltage requirements of the motor. Generally, 50-100 turns can be wound for experimental attempts. After the winding is completed, fix the coil with insulating tape to prevent it from loosening.
Handle the coil joint: Use sandpaper to gently polish the paint on both ends of the coil to expose the metal wire for subsequent welding.
(II) Assemble the rotor
Install the permanent magnet: Fix the permanent magnet on the rotor bracket according to a certain polarity arrangement. You can use strong glue or fixing clips to ensure that the permanent magnets are firmly fixed. Note that the polarities of adjacent permanent magnets should be arranged alternately to produce a stable magnetic field.
Install the shaft: Pass the shaft through the center hole of the rotor bracket and ensure that the shaft is perpendicular to the rotor bracket and firmly fixed.
(III) Assemble the motor
Fix the stator: Install the prepared stator coil on the motor bracket to ensure that the coil is accurately positioned and does not interfere with the rotor.
Install the rotor: Install the assembled rotor on the shaft and place the rotor in the center of the stator coil to ensure that the rotor can rotate freely.
Connect the circuit: Use welding tools to weld the power connection wire to both ends of the stator coil. Note that the welding should be firm to avoid cold welding.
Testing and debugging the coreless motor
(I) Power-on test
After completing the motor assembly, connect a suitable power supply for power-on test. First, adjust the power supply voltage to a lower value and observe the operation of the motor. Check whether the motor can start normally, whether the rotor rotates smoothly, and whether there is any abnormal noise or vibration.
(II) Debugging and optimization
If the motor has problems such as poor operation and low speed, debugging and optimization can be performed. For example, you can adjust the number of turns of the coil, change the arrangement of the permanent magnets, or adjust the power supply voltage. By gradually trying different parameters, you can find the best working state of the motor.
Through the above steps, you have successfully made a coreless motor! This is not only an interesting practical experience, but also allows you to deeply understand the working principle and structural design of the motor. During the production process, you can also improve and innovate the motor according to your own ideas and needs to explore more possibilities. Come and try it!