3d-printed brushless Motor - Explore max. RPM (make it explode)
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- Опубликовано: 19 дек 2016
- In this video I'm testing the maximum rotation speed of the 3d-printed brushless motor. The destruction of the motor is intended, since I need to know the safe operating range.
As precaution, I've arranged cardboard boxes around the motor in order to catch flying pieces of debris. In addition I positioned myself far away from the plane of rotation, controlling the motor with the transmitter of an RC-car.
The 3d-model of motor is actually published on www.makesea.com/brushless-motor
For the tests I've selected the "bad" magnets (I knew they will break) with the lowest magnetic force. As a result the Kv was higher than the value calculated in the tests on makeSEA. Anyway this doesn't affect the maximum achievable rotation speed of the 3d-printed rotor.
Conclusion: it breaks at 30'000 rpm!
That's quite good. A regular propeller for an RC plane has a lower limit. Considering variations in 3d-printing quality, I'm thinking it's absolutely safe to use the 3d-printed brushless motor up to 15'000 rpm. 
Наука
The other 43% of Magnets flown to 5th Dimension.........
who else is from great scott? Good work christoph, you are in his new video!
The banana boxes seemed like over kill until they didn't.
0:55 If you look closely, you can see the rotor expanding when throttling up due to centrifugal force
Technically it is called centripetal force - but nobody is going to hold it against you.
I'm very impressed! I wouldn't have thought a 3D printed motor (abs or pla) would have held together above 8-10 thousand RPM. As they say, Experimentation requires sacrifice. In this case, around half of the magnets were sacrificed to the Brushless Motor gods. ;)
Send one to the slomo guys to film at 10,000 fps!
wtf
I know this is old but YEEEEESSSSSSSS
tone down the antisemitism dude >:(
@@glowiever was there another comment that got deleted? Because with the comments present now, I don't see how you see antisemitism here
Wow, that's wild! I'm amazed you were able to produce a working motor from a 3D printed bell housing. Thanks for the vid!
thank you for satisfying my OCD with that frequency analysis... i just tought it and you've done!
Good lord, that is a lot of energy released. Thankfully, your smart and had some boxes for protection.
I'm so impressed though. Beautiful build.
Nicely done sir!
If I were doing the test, I’d be a lot more scared of bouncing shrapnel. Full enclosure with a layer of cloth scraps outside the box.
Thanks for sharing Christoph. The only thing you need now it's a high speed camera.
I am sure you will find the remaining 43% of magnets in time...Expectadly (or innexpectadly) sticking to ferrous objects.
Great stuff.
I just hope you start making more videos Christoph. Hope somehow you do just that for us all on RUclips. Hope you had a great and Happy Easter too.
Mad professor! Nice work, keep it up.
Boy! When it lets go, it lets go! Thanks for sharing!
actually when i matched the notes of 1:30 with my guitar, it reached D5 at very end before it exploded
D5 itself is 592hz
i've tried 494hz which is something around B4, but it didn't match at all
B4 is 498hz, it still sounds way too low for B4 (like one or two notes lower from my hearing)
so it's actually spinning around 35000 rpm
Finally someone who understands music is math, we are cursed with knowledge
-Thanos
1:42 i was literally like:”which calculations are going on here?”
Me: Did you just invent reusable grenades?
US army: *WRITE THAT DOWN SOLDIER*
Reusable grenades are actually a thing
Thanks for testing this!!
here from great scott!! this looks amazing :D
GENIAL este proyecto. Saludos Cristoph
Balancing was NOT the problem. It was not vibrating on the stand. The Bell simply flung apart. it was not strong enough to handle the sudden onset of power. Although it probably would have given up any way. We don't make hi power rotors out of plastic for that reason.
again, love your work!!
And that's exactly how R&D is done. Kudos!
A single magnet weights 5.8g. I've calculated a tension along the outer surface of the rotor of approximately 3'000 newton at 30'000 rpm. At 18'000 rpm the tension is around 1'200 newton. A regular propeller for an RC-plane is specified to spin at 10'000 rpm, at this speed the forces in the rotor are at 400 newton (40kg). Anyway with this test I learned, that there is a safety factor of almost 10, when I'm using it on my RC plane.
Maybe you can calculate the speed of the propeller tips of a regular toy-drone, and figure out what happens if that gets in touch with a somebodies eye ...
Thank you for this very important information
GreatScott!
good experiment and Mathematical analysis....
That's really nice!
Very nice Video! Enjoyed to watch, thank you.
If I remember correctly from other videos I've seen, the failure happens at the layers of the print, then forces cause it to crack along other parts of the print.
I'd suggest printing a mold and casting a solid piece, rather than a layered product.
You can actually see the plastic expanding above about 10K RPMs. I was waiting for the kaboom. I think 30K might be a bit liberal of an estimate, but no way to know for sure without more data. Excellent project! I could see this in a puller truck or dragster, simulating fatigue conditions, where you can only get X runs out of them before catastrophic failure
I wonder if you used two band style hose clamps around the outside opposite one another if that would keep it from fragmenting?
Amazing!!! Would liked to see the disintegration on a high speed camera...
Interesting idea. It would be fascinating to see if a Halbach array rotor would improve the concept where the magnetic plastic is not viable.
awesome work!!
Right to the point.
You're a good man.
At this rate in couple of years we will see electric vehicles with 3D printed motors serviceable by the end user(AWESOME). Great stuff, you sir earned a subscriber. Smashing job. Mad skills but maybe it could use a bit more balancing.
isn't 30k rpm also the limit for most steel/aluminium motors?
No. Motors in EDFs clock 40-50k without trouble.
Wow. Have you tried using Nylon based filament? Also printing the housing without the engraving to avoid some unbalance.
Pretty badass, but how is the torgue? Would it be able to handle gearing to spin a turbo to any signifigant speeds?
Interesting to finding these videos of how high rpm's can take out things when similar things happened lately with various spinners. I'm sure you already thought about it. but I think the new 3d printers that can lay in carbon fiber support into printing would be a pretty good fit for parts like these.
Saw it tested a bit on the hacksmith's channel how 3D printing a spinner with a markforged printer that lays in carbon fiber reinforcement make it able to stand a fair bit of force.
I am thinking of make a simple 0.4cm thick spacer for my boat propeller, it just needs to be a bit further out at the tip to reach the bolt tightness, it goes 5000RPM max. Here I see yours going 30,000RPM. Do you think a simple spacer like that would holdup in the ocean? I just dont want it to fall apart while cruising however based on my experience with 3d printed parts they are very very strong.
I wonder if high temperature PLA would make the engine stronger. You know, where you bake the part in the oven. You would have to account for the shrinkage though. Thanks for sharing, can't wait to see more!
need to figure out how to print a groove for some of the some super strong fishing line wrapped around the external housing. to keep it from expanding to the breaking point.
291km/h thats incredible... im surprised the thing didnt melt from heat before it exploded.
we all love explosions. !!!! nice work. good test. at thos speeds I'd be behind a wall ;) ~Russ
I think you need to use some setscrews so its more balanced. I dont know what kind of infill you have setup but you might want to try 100% concentric pattern. Also turning up the temperature will help some with layer to layer adhesion (or put your printer in a bananabox so the last printed layer does not have the chance to cool).
Have you considered repeating this test with a statically balanced motor like the one you sent to the Flite Test guys?
WHAT A BEAST!
Thanks for the immediate pay off at the start of the video :) What material was this printed in?
PETG
Is that less costly to make sir? I always wanted to buy one bushless motor as a project of mine, however its kinda expensive.
hi christoph laimer did you try this engine with another design ? and is this your design or did you take somewhere ?
May be a stupid suggestion but have you considered putting, whats the term, flutes? in the housing, like they do in saw blades, that stop oscillation from traveling through the structure and prevent shattering?
hey would you help me....When i try to test the motor with servo tester it just shakes left and right, only one time it actually spun and thats because i helped it with my hand but i cant get it to spin anymore.
I wonder how much faster it could go if you had some trivial reinforcement constructed in the spirit of the project. I'm thinking of something called "strapping tape" which is tape containing long fibers. It is used to assemble cardboard boxes, and reinforce them to prevent bursting. You can easily find a roll at an office supply center.
And when it does break, the strapping would probably make it less of an explosion.
Also, what if you made the walls 1 millimeter thicker? Why did you make it the thickness you did, where it supports the weight of the magnets? It must have been designed to have a particular strength. So the real question is, did the failure point match the designed performance limit?
Iv worked with that kind of tape in the past. It is strong stuff, if the motor was made with that and some of the carbon fiber filament maybe with thicker walls 20-30K speed would be within reason. would be interesting to see what one of these motors would do inside a suitable EDF housing with a good Propeller.
What would be the centrifugal force of the outer casing at 30k RPM with the weight of the magnets and the diameter of the shell? I would reallly like to know that and I assume well over 1 ton
Swiss quality! ;-)
Suggestion,
Try using the iron filled filament for the core?
It may help the flux lines and reduce air gap
no need, why, because the outrunner would of gone higher if it did not mechanically failed first.
Very good, pay attention to safety！
Nice video ID :)
Power of moment of inertia and centrifugal force .
from great scott; 30k rpm is impressive! I wonder would banding it with zip ties help ?
Which 3D printer did you use to print the project?
Try printing out the motor casing, and then making a plaster or sand mold, and pour an aluminum one. It's relatively easy to do, and you 'might' not have the exploding shrapnel problem.... but that is impressive for a 3D print.
you might be able to push it a bit further if you use polycarbonate instead of PETG but it is a bit harder to print without an enclosed print chamber
If you would wrap carbon fibre tape on the outer perimmiter, how much rpm could you reach then?
how much centrifugal force was being put on it? iam planning to build a motor that will get out 15k - 25k RPM (a brushed one tho) and i want to know if it is safe to make it out of PLA or PET-G
You can also try to make the rotor of the motor even thicker so it doesen't destroy for the centrifugal force
i wonder how much of a difference it would make to have a steel band or something around the outside
thanks for your awasome work, may be if you envolve ir with steel wire could resist the internal magnetic force
awesome sound ;-)
I could see the plastic housing expanding as the revs increased due to centrifugal force. The weight of the magnets must be too strong for the structure. At least you now know it's limits! :)
Six seconds in and I already exclaimed "Jesus Christ!"
You seem like the guy to ask a motor construction type question, but would a motor's bell with two sets of inner and outer magnets around the fixed stator winding's have any improvement in torque?
That's certainly challenging. The centrifugal forces of the inner magnets are difficult to handle (without making the air-gap too large). Other people are experimenting with an axial flux arrangement.
Needed to ramp rpm slowly to capture an accurate reading while eliminating forces due to acceleration.
if the core rotor and housing made from steel. it is working or it does not working at all ?
Excellent test. I think additionally required temperature test.
Probably less spectacular ;-) ... But you're right. This test will tell the maximum continuous power. So far with only 100W it was always far away from melting.
That's a fantastical 25,100 Gs of acceleration! Damn.
Nice number - I like physics. The magnets, a bit closer to the center, are "only" accelerated with 23'000Gs. A single magnet weights 5.8g => each of the 12 magnets pulls with an equivalent of 134 kg. In addition there is roughly 1.2g plastic per magnet. The tension along the surface of the motor between two magnets is approx 300kg.
@@ChristophLaimer That's CRAZY that it held together like that... Pretty amazing.
what voltage and amperage has this motor as I do to buy or in which country this motor is and how much money that moy says
hello good afternoon friend how can I buy this type of engine and what store sells it, distributor and how much is the price...
What if you coat the case with a layer of fiberglass and epoxy resin?
55 seconds. Center of the drum. You can see it grow in diameter. At the axle, you can see vibration. Three windings of carbon fiber strand with epoxy added after each winding, should greatly improve the rigidity of the rotor. Twill weave tape would be ideal if you can get it. The outer surface of that drum may be rough enough to promote adhesion. If the Carbon Fiber epoxy reacts with the plastic, you can try your favorite water soluble glue. If carbon fiber is too expensive, nylon would be my next choice.
With some Experiance, you can hear, that the Bearings have to much Space.
Bearings are not made to be used like that.
They are designed to be "pressed" on a Shaft or "pressed" into a Bore or both.
Otherwise they have a huge Gap between Balls and Rings.
In Germany the DIN for the Gap is market with an C.
For a printed part thats kinda very fckin awesome ^^
you should do a collab with slowmoguys and see a motor like this explode in slowmo
THIS
You've answered the question, "But does it blend?" by doing it to itself: self-blending! WEE!
nice
perhaps making the outer casing thicker and balancing it afterwards.
With an electromagnet motor instead of a simple magnet, we create the magnetic magnet for more replussion so everything will depend on the current.
hi, was this printer in abs,pla,petg,... or something else? Also have you done research on the effect of the wire gauge of the windings on torque and speed?
Rotor and Stator Shield are PETG, Winding Core is maggnetic PLA from ProtoPasta. See www.makesea.com/brushless-motor for all my lessons learned ... The wire gauge has no effect on torque and speed, BUT on efficiency. Keeping the current constant, a thinner wire has a larger resistance, and efficiency decreases. However the number of turns and the current have an influence on the torque. With a thinner wire there it is possible the use the space in the slots for more turns and have the same torque with a lower current. Finally if the slots are fully filled with copper-wires, efficiency and power remains almost unchanged at different currents, while only Kv changes.
Christoph Laimer thank you very much.
No plastic for magnet holder, metal only :) And huge vibration already was after 3S test.
when you have heavy release the planes of the 3d-printed brushless Moto, thanks
hey Christoph ! I actually bought a novarossi pylon racer and cant get it to max rpm. Can you please help me out. I don't know who to contact and I desperately need to get it running.
whaoo the vibration destroy it .. very good motor
The speed destroyed it, not vibration... well, I guess it vibrated pretty violently after the rotor came apart... because of the speed...
1:24 you could make a sweet remix with that😜
Very Best.
i saw a video of a person that reinforced 3d printed object inserting steel wire in it ,maybe you can do the same but with smaller wire and more turn like the reinforced concrete...
Cool here's an idea to solve weight explosion. Put coils on outside and have center be the magnets
The tangent speed is high but the acceleration is even more impressive. Around 25 000 g. Of course the centripetal force required to maintain that acceleration of heavy magnets is huge. That is why the rotor casing failed. A layer of carbon fibre might improve the tensile strength and allow higher speed.
i would NOT want my face to be where that box was :O
I blinked hard when the motor outher case exploded lol
sick!!!!