Integrated motor assembly

Post date: Apr 6, 2013 7:40:14 PM

With the drawings from our integrated motor completed (if something like this can be considered finished...), we found a very kind person to turn many of the parts (axle, stator plates, ..) on his lathe for us!

Stator plate for the front, with space to hold a 62/22 bearing.

Spacer that goes between motor and adapter plate.

Bearing installed and secured. The holes supposed to secure the stators to these plates are not arranged on a square, making it harder to mark them. Here my CNC mill came in quite handy :) They were practically spot on!

The axle is put in and secured on one side by a circlip. Then, the rotor holder is installed by heating it to 200°C, at which point it has expanded enough to easily slip over the axle. After securing the magnet disc, the contraption at the bottom pushes on the axle to keep the rotor from smashing into the stator (until the bearing at the other side can be installed).

Almost finished with the assembly. Now we need to arrange the threaded rods so that the air-gap is as uniform as possible. Unfortunately, we ran into some problems here. The distance from bearing to bearing seemed to be smaller than expected. If we just had an additional 0.5 mm! Also, the front rotor discs has a slight wobble in it. Not sure yet if this is problematic, but it makes tuning the air-gap even harder...