Editors:

Marcin Jakubowski

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Graphic Design:

Jean-Baptiste Vervaeck

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Version:

Date:

Motors

v19.05

First Edition

Open Source Ecology Design Guide Series

Motors - Table of Contents 1

Summary – How stepper, electric, hydraulic, and pneumatic motors work. Different sizes and forces, their limits, and how to increase torque via a geardown. Speed and range of applications. Design of motors. Application – you will understand how to select and size a correct motor for the task, and you will be able to determine to within calculable limits prior to testing whether the selected motor will do its job. You will also understand basic design so you can begin building your own motors

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1. About Motors
1. What is a motor - diagram and main parts. Motor vs Engine.
2. How motors work
3. Why motors work
4. Applications
5. Types of motors: stepper, electric (brushed, brushless, AC), hydraulic, water pneumatic, turbine, soft motors
6. Reversible motors - using or producing energy
7. Conservation of energy and theoretical efficiency limits
8. Selection of motors for different applications
2. Design considerations
• Calculations and power density
• Heat dissipation and thermal design
• Wiring and plumbing
• Best practice for selecting a motor - direct drive, no gearing
• Couplers and set screws. Shaft shape. Tapered shaft. 3D Printed couplers - basic coupler calculations
• Selecting the type of motor by application: torque and speed
• Control with the OSE Universal Controller and relays - hydraulic, DC, stepper, but not brushless
• Design of an electronic speed controller for a brushless motor
• Control logic of stepper motors and other brushless motors
• Geardown - give me a lever long enough and I will move the world - calculations
• System integration
• Scalability considerations - pancake, size increase, forces

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Motors - Table of Contents 2

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• Designing your own motor
• Designing a useful, scalable brushless motor
1. FreeCAD Brushless Motor Designer
• Designing a useful, scalabile hydraulic motor and pump
• Designing an open source, 3D printed stepper motor
• Visual Bill of Materials
• FreeCAD Part Libraries
• Shaft and bearing design
• Geardowns
• Design checklist
• Building your own motor
• 3D printed stepper motor
• Pancake brushless DC - motor - to be 3D printed - for metal cutoff saws
• Halbach array motor. Laimer website.
• 3D Printed Water Motor
• 500 PSI 3D Printed Hydraulic Motor
• 3000 PSI Hydraulic Motor
• 3D Printed Turbine - a rotary tool
• 3D Printed Hydraulic Robot - video
• Tools and materials
• Build techniques
• 3D printing
• Copper coiling
• Working with neodymium magnets
• Shaft and bearing alignment
• Building for structural stability and calculations
• Stacking pancake sections
• Hall Effect sensor feedback
• Overall cost
• Build checklist and quality control
• Testing and data collection

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Motors - Table of Contents 3

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• System Integration
• Mounting motors
• Adding a machining spindle to a motor
• Electric
• Hydraulic
• Making and installing couplers
• Running motors and stacking motors in series or parallel
• Measuring torque, speed, and power

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Notes On Using this Guide

OSE work builds upon these great open source projects:

ABOUT: This is part of a design series on general machine design aimed at basic competency in the design of all 50 Global Village Construction Set machines.

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HOW TO USE: You can use a QR code reader to scan the bar codes to access content online.

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COLLABORATION: This is a collaborative effort. You are invited to help edit this guide. You can edit this document or make a copy, make your edits, and email us describing your proposed changes. To join our open source product development effort, join our Developer Team, or get hands-on experience in our Workshops. Email us at info@opensourceecology.org

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