How to make a brushless dc motor at home
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- Опубликовано: 8 сен 2024
- Suport me on Patreon at : / iulianberca
New outrunner motor : • High efficiency 35kW B...
Website:
www.masinaelec...
How to make a brushless motor step by step.
For business enquiries :
email: iulian.berca@gmail.com
See also 3D modeling of the motor.
• Video
See my website with the winding calculations
www.masinaelect...
Designing a brushless motor from zero
Magnets: 40pcs 35UH
Slots: 48
Winding : AabBCcaABbcCAabBCcaABbcC
Nominal Voltage: 300v
Max amp: 150A
Weight: 17Kg
Speed: 2600rpm
Hall sensors: TLE4905 Infineon
Software : Autocad 3D Inventor 2015, FEMM 4.2, MotorCad 7
Usage: electric car, opel agila
I have been rewinding Brushless motors for sometimes now. I have to admit yours is one of the Finest I have seen. This thing can power a small plane, just by looking at it. GOOD LUCK. I do hope that you will share some more Pictures/Movies. GOOD LUCK :)
Would you please help.
I am not an that expereinced in electric motor but I wounder how good or how bad would be my design. I designed a BLDC motor and that seems to be perfectly good enough on paper. Would you please try it in a simulator or tell me how to make it be better even from your knowledge. I would ask you to advice me to use a specific stimulator or such but unfourtuantly, I have a REALLY BAD PC.
Wow! A skilled engineer sharing knowledge. Thank you!
I like the blast shield! Ive only done a couple projects that made me hide behind a wall, you know its serious when...
On 2:18, wooden particle board. To protect the legs.
nu cred ca tine PAL-ul ala la niste shrapnel la 2600rpm
Now try adding a spinning lawnmower blade to the thing and you'd have a battlebot!
WOW 👏👏👏👏👏
this is amazing. U could build ur own emergency generators, electric bikes , etc with this.
Good relief that you have made it to work and not have to discover that nothing worked at the end. Great careful job man!
Great motor and excellent skills, If that motor was made as an outrunner rather than an inrunner, it would increase its torque by more than one third and could be used to power a small aircraft. Well done.
Beautiful work. A bit bigger than was looking for. It needs to go on my Skateboard.
Increible desarrollo. Felicitaciones!!!!!
Incredible development. Congratulations!!!.
Try to do the standard test s (ANSI or IEC) in order to benchmarking.
Measure no load losses, efficiency, etc.
Congrats again!!!!!
The saturation is to increase torque at a stable rpm , electric motor s are best made to suit there job , ideal working rpm an torque required, is controlled in wave length formation , it is a very nice build an I'm impressed, I work with highly advanced motors everyday , An for a home build is probably the best iv seen , cooking system im not to keen on as fan cooling is much more preferred way . But all the same good work 👍🏼.
Un potențial de piață enorm.
Beautiful work.
Sorry if someone has already asked but I was just wondering what the efficiency of the motor is when it is running at or near capacity. I gather the water temperature must be kept above the dew point at all times. That is a very impressive design and excellent quality of construction. You should be very proud of this beauty!!
im 16. i know almost nothing about brushless DC. i have a test tommorow. what am i doing here. I know exactly what im doing here. they dont teach this stuff at school so here i am trying to reinvent the whole thing. This is probably the coolest custom motor ive seen in a while but i need to study
I disagree, I learned all about motors and magnets in my class this year
You can learn this stuff in electro technical school.
the first class about magnetic induction, it was on the 6 year of school....
There is no such thing as a brushless DC motor... its a 3-phase AC motor running off a VFD, which has a DC power source...
There is no such thing as a motor... its a rotary system of magnetic fields and coils setup such that the pole pairs continuouse moves causeing rotation. Its just an electromagnet
Wow this looks like a nice, production-grade motor.
Very nice, its an inspiration to me, im thinking of making my final project at electrical engineering course with something about the brushless motor, keep engineering!
Wow, Smart man. 45Kw is big power. Impressive that you built it alone.
Good for powering small EVs too.
Julian you made a fantastic job there, congratulations.
You are a serious engineer! I am just a electronic technician with years of experience I say you have a great design.
its shit. you cant feed 1 khz waves to steel sheets
1 khz is nothing, and anyway I don't know what you mean by applying waves to steel sheets, you must be talking about applying the magnetic field to the steel sheets, but even that is a standard practice in electric motor engineering.
Mark Osborn steel sheets struggle with 60 hz and this dude here puts them at khz range. that is why most of the motors for commercial use are long and have smaller diameter. the more sections you have-the higher the frequency needed for the rpm. this means that this is torque optimized motor, but its very bulky for the torque it can deliver. also long axis small diameter rotors are better than this short thick one, because of the lower inertia- a big problem with EMs
Are you an engineer or just an arm chair technition?
Mark Osborn im far from professional engineer as you can tell, but i know a lot of stuff and go into detail on everything
Thank you so much for the website link of the winding calculations! Wow! Never knew they had one. Great idea!!
That motor is a Polyphase, Permanent Magnet, Synchronous motor. It may be driven by a polyphase inverter that runs on DC, but *Brushless DC motor* is a misnomer. Very nice work, by the way!
I want you to know I don't really cuss... So HOLY SHIT thats an amazing amount of work man, I am impressed. Id only for this for school and maybe a job, and this is just... wow.
my god man, you are a genius
Mandru ca sunt roman cu oameni ca tine :)
you should make these as a business - looks good. I would buy 2 for both rear wheels if can connect easy enough...
Did anyone else see a spark at 1:47 in the upper left hand corner?
Very very cool motor. I've recently become obsessed with electrical motors and Li-ion batteries. I hope you put that monster in a motorcycle ;)
That's the laser from the tachometer, not a spark
How many parallel paths you chose?
Did you laser cut the stator or do you have a stamping die?
Quite an impressive piece of engineering, sir
These would make excellent hub motors for vehicles!
Good work plz try to achieve same using permanent magnet or using any further low resistance conductors which will reduce more power consumption. Thank u.
so many nice videos for a change thankyou for the over the top unity on this adventure that is in my soul ary nice
Nicely done. I would love to build one myself
M-am uitat la video prima data.la minutul 2.20 am oprit video pentru ca am ramas impresionat de tine ,am simtit pe vocea ta ca esti roman ..
beautiful work. Thank you for showing your wonderful motor. That represents a lot of work and money to make.
Holy moly this is amazing, thank you for sharing all your hard work! Even at 45KW this would blow small car gearboxes :)
That's sick! You should put it on a e-bike or something.
too awesome. love the unique design need to show some links for the build of so it can be replicated if thats ok with you
Excellent work but nothing mentioned about control electronics.
Probably Vedder's vesc on steroids
Julian that was truly an impressive "diy" (i think your a lil above the diy moniker!) motor you created. id love to see its end application. good video. teach us!:)
do you have any of these made to look like a car wheel? instead of water cooling it, could you use dry ice?
Does the controller make the motor beep before it starts? That beeping is very important because it alignes the coil's as per Gerald Morin's video. Great work...I would think that a motor that works with the laws of nature would not need a cooling system? That would mean there is frictions which is against natural law. Just a thought that makes sense to me.
Felicitari !! Superba treaba, salutari din Londra
Congratulations on such impeccable work.
beachcomber 20th 8 ū
Nice hardware set up, test place and video montage TERIBLE
Very impressive work! But I have to ask, is it really wise to have an open water container so close to the all the various components? Seems like a cover, even a loose one, would be a good idea.
Bravo, esti tare de tot!
Very well done! I worked at Baldor where I used to machine 10000+ hp motors and the tolerance on machining was usually +- .002. I've always wanted to try and build something like your motor using solid copper bars like the ones we used, but permanent neodymium magnets. Have you tried anything like this?
How do you estimate motor capacity during design? Is it based on magnet strength, copper wire size, turns, input voltage and amperage? Is there a calculator available for such sizing calculations? Thanks and hats off to you! Amazing piece of frugal engineering and design.
your are an inspiration...
VERY NICE A LOT OF WORK
I am really impressed of the quality for a home made (or garage made) motor. I am wondering about the distance between magnets and coils. Isn't that suppose to be very close ? If you put kevlar and epoxy or whatever, isn't that going to increase dramatically the distance ? And also, what are the specs, torque .vs. current, power in .vs. power out ? Very impressive built. Can you propel a car with 4 of those ?
could you do one of half the voltage??? and make it opensource, this particular motor could be use to make an electric motorcycle
Jorge Flores I’m looking to this too!
A real Engineer.
Absolute perfection I would luv this motor I'm interested to know with such low voltage/amps and high tork could you run it from the earth like they used too with telecom cables then gear it up to a alternator
350pauli is that even possible, and do explain more or send me a link cause that’s some Nichola Tesla shit
Julian man, you’re a genius. Hey, what happend with the 3D modeling video? This is aamzing
wow your delta brushless motor has proportionally more torque than a tesla induction motor, you should do a project with it, an E.V or something
First open source motor on the market for EV cars
www.masinaelectrica.com/open-source-60kw-motor-high-rpm-version-2018-in-construction/
well... bldc motors have proportionally more torque than induction motor's, that's nothing new. But BLDC motors are more expensive, and for high power applications, not as efficient due to magnetic losses due to eddy current. Instead, induction motors can compensate electric losses with magnetic losses more efficiently in high power applications.
So approximately everything above 100 kW is more efficient with induction motors.
Bravo Iulian , foarte tare proiectul tau ! Felicitarile mele. Te-ai gandit si la o varianta mai puternica ... 100-200 kw ?
beautiful job well done. I have bild my own some smaller, but I really would love to build a bigger one, but I am in need of some thick aluminium plates which are very very expensive here in denmark....!! :(
Salut.multe aprecierii,bine lucrat
Very nice piece of work ....... did you make any sense of it ' s efficacy ? How long have you run it for ....... a soak test yet ?
Reverse the hookup and U have a Great Alternator for a wind or hydro setup.
Fantastic job on your project. Any good resources for designing the coil to your application?
man, this is awesome. you are the engineer!!!
Fantastic job! Very professional, thanks for sharing.
thanks iulian for making this. I myself want to make a small out runner 5055 size, please give me some ideas on how to laminate it as in a small motor I can't put paper for lamination, please help
You are awesome iulian
Hi. Have you ever consider the metal parts that can be attracted by the permanent magnets? These thing can cause serious problems...
Excellent job!! Congratulations Iulian
Fantastic work mate, from the UK
So this would be around 60HP peak power?
If so, this could work great in a small electric car
Motorcycle :D
what if you could make a rotating casing (that goes around the cover of the motor) and put a tire on it. cant you use 4 of those to quadruple the effect? (basicly using each motor as wheel)
There is a very cool version of that: ruclips.net/video/l2PJmg-cEIE/видео.html
Also it's probably not that practicle. You have to consider the fact that dampers are for a reason in cars.
Interesting. I also wonder what would be more cost effective in an electric car. Having 4 scaled down versions of this motor that only require basic air cooling or having one bigger motor like the one in the video and having to deal with heat with the help of a liquid cooling setup...
Theodor Butters .i need ur contact
You are really smart!! Very interesting video! Thanks!
This motor looks suitable to power small sport aircraft. I wonder if you can tell me the equivalent horsepower?
60.....
How do you get the supply of 150A power I imagine you might trip the neighborhood?
150amp isnt that hard, u can get that from a very cheap welding machine, the thing is that he is getting those 150amps at 45kw, wich means that he would need a 300 volt three phase supply, but in this cae he is feeding it with batteries, however, u can get that amoun of current with a enterprise power feed.
Well this is excellent! thank you for showing. pierre from New Mexico
Does this stator design let you wind coil on a machine and then just insert them into the stator or did you have to wind each coil in-situ by hand ?
Also, what dimensions and capacity are those lithium cells and how much do they cost ?
How did you manufacture the stator laminations ?
Did you consider the halback configuration for increased field strength ?
How well would this be if run as a generator?
nice motor for metal milling
Would you please upload some load tests?
Yeah, you connected some generator that does 230V, but no one knows what current.
I just can't imagine that much power in such a small motor. I realise that cooling is major problem with high power here, but I wish to see it making like 20kW for 10-20 secs.
Nice work btw.
Nice motor! Could you please post some no load figures (Amps and rpm for two or 3 different rpm) as well as the terminal resistance Rm and Torque-constant Kt or Speed-constant Kv of your motor? Thanks for sharing!
This is sensorless, correct? If so, the low speed performance is amazing. Very smooth.
did you ever use this motor to run a machine like a bike or a car can be use for that?
and how you can control the motor speed and torque?
awesome work iulian God Bless !
I am thinking to use it in electric car imagine that u use 4 motors of this on each tier the car power will be be 4 * 45 kw = 180 kw with 2600 rpm thats WOW thanks man this is what i am looking for
Buna ziua,
Felicitari pentru acest motor realizat.
Cateva intrebari :
- Se poate folosi teava de inox cu perete de 3-5mm cu o greutate mai ushoara?
- discurile taiate cu plasma pot fi din dur aluminiu?
- Rulmentii pot fi ceramici ? ( coeficient f mic de frecare si mult mai rezistenti decat cei metalici)
Hi its Wonderful thing you have done but not suitable for amateurs. So much details are hidden. Plz do video exploring more.
Beautiful work! But don't you get a lot of eddy currents in the copper cooling jacket?
Interested in the controller you made to spin it at such a high rpm.
Я полагаю,что подобный двигатель может состоять полностью из обычных неодимовых магнитов,а не электромагнитов,изменяя наклон угла магнитов на любой из сторон можно управлять скоростью вращения.
Nice work !!!! I like the look of it too. The rotor being open (on spokes), does that help or hinder with cooling, fly-wheel theory, etc... I would like to hear more about your plans with this unit and the latest unit you designed and made... Also, when you are running the motor very slow, does the coils or the controller get warm or hot? Yes, I see that you have a heat extractor incorporated on the outer casement, but, does it still get hot, or does this system not even care weather it is spinning slow or fast? Oh, and also, how much does running the sensor assist in being able to run at the low RPM's, while holding that massive amount of torque... I am blown away, but this. Have you played around with what the lowest supply voltage you can run, or is it already at its minimum... or maximum? ... Again, Nice Work !!!!
very cool design, big respect !
Impressive craftmanship, setup and performance. How do the 35 kW and the 45 kW motors compare regarding in cost/benefit?
very nice job
That's one cool project, great work. I have been doing research trying to find out why electric vehicles use brushless inrunner motor and not outrunner brushless motor. I know for a fact that outrunner motor offers more torque compared to inrunner motor, has more efficiency but less speed. Why are they then not used on electric cars?
Having the magnets outside and the stator inside can't be the core reason why they are not used on cars, what do you think??
ruclips.net/video/hLtxzPgDoSw/видео.html
You're amazing! Hope you are adequately employed (then again - you must be pretty well off to afford all of this)
Julian...can you explain how you get the torque? Some people do something similar but can't get torque especially at slow speeds? What would you say is the secret to great torque? Thanks!
hi. I like the brushless motor cooling a hot metal. what happens a bearing in the center of the motor?
isn't there cooling a bearing with pumping an oil or a water?
On the Avasva you can count on professional help with problems and technical support.
Nice work!
Can this be used for EV?
I just realized that you were talking on the left top corner lol
WOW GREAT JOB