Electric Motors

This large, high pole count motor was an experiment to make a nearly stepless BLDC, with 51 slots an 50 poles giving 2550 cogging steps per rotation for essentially no torque ripple. However, an unwanted side effect of this configuration is the loud high pitched whine it makes at full speed and the potential for running into ERPM limits on the controller.

This motor was an attempt to reduce manufacturing cost of the core with a bent-plate hollow core reducing mass and material needed while still having a respectable flux density. In practice, It had less torque than predicted but still was able to provide a considerable amount of power.

This flat, large diameter motor was designed for large props and a very low operating speed. It used laser cut stell laminations and thick solid core windings with a high turn count. 

This motor was built using the large magnets from old hard drives and fit neatly inside the machined case of one of the drives. It was breifly used to drive a test vehicle but the printed shaft adapter proved to be a weak point.

This motor used a laser cut core with built-in heatsink fins for continued high-power operation. Designed to drive a go-kart, this motor struggled with starting torque and was later used with a propeller.

This motor was designed for my first propeller car and paired well with a 30" prop to produce around 150N of thrust. It was the first motor I made that used a laser-cut core and this allowed it to have significantly higher torque for less winding.

This was the first large custom motor I designed, and it performed reasonably well considering that it was all plastic. The stator was printed out of ferromagnetic PLA which helped somewhat with torque.