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Design and Construction of a High-Performance DC Motor: Project Overview

This project focuses on the design, construction, and control of a homemade DC motor capable of operating between 100-900 RPM with a control system ensuring speed regulation within ±10 RPM. The motor features a custom armature, stator, and magnet configurations, as well as precision controls involving QNIX and QMotor encoder systems. Challenges faced during construction included machining issues and securing the magnetic components. The project reinforces practical engineering skills and teamwork, culminating in a competitive demonstration of performance.

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Design and Construction of a High-Performance DC Motor: Project Overview

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  1. ECE 496 DC Motor Design Group A December 01, 2003 Mark Goettsch

  2. Introduction • Project Objectives • Team • Construction • Controls • Results • Web Development • Conclusions • Questions

  3. Objectives • Each group must design, construct, and control a DC homemade motor, commutation system, control system, and a speed measurement device such that the machine assembly rotates at selected speeds. • Build a motor capable of turning 100-900 rpm • Control the motor within 10 rpm

  4. Team Structure

  5. Construction • Armature • Shaft and Insulation • Windings • Stator and Magnets • Baseplate, Bearings and Supports • Encoder Mounting • Problems

  6. Armature Plates • 3/16” thick steel plates • 2.5” diameter • 17 total for approximately 3” • 8 slots, ½” diameter

  7. Shaft Steel 5/8” Diameter 20” Long 4” cut down to 3/8” diameter to fit encoder Insulation Polyurethane spray from Lowe’s 4 or 5 coats Insulation Paper Shaft and Insulation

  8. Stator • 4” steel pipe • 3.625” diameter • Adjustable air gap

  9. Magnets • 2 Pole • ¼” thick • Arc shaped • 1.875 long • 12 total • 60 degrees of separation between magnet pairs

  10. Bearings and Support • Steel baseplate and support plates • Steel encoder plate • Pillow block bearings5/8” diameter

  11. Commutator Brushes • Helwig Carbon Brushes • Concave Radius • 0.375x0.750x1.000 • Copper over PVC • 1.5” Long • 8 segments

  12. Construction Problems • Machining time • Adjustable air gap • Securing magnets

  13. Controls

  14. Approach • Focus on Steady-State Response • Simplicity • QNIX and QMotor

  15. Encoder • US DigitalE3-1000-375-IHM-PKG3 • Optical Encoder • 1000 CPR

  16. Wiring

  17. Control Problems • Working Computer • Learning QNIX and QMotor • Program quitting prematurely

  18. Bonus Day Mounted Motor Unable to Spin 6 Points Competition Day 300-500 rpm range ±2 rpm for 320, 400 and 480 30/30 points for steady-state No points awarded for transient Results

  19. Web Development

  20. US Digital Corporation11100 NE 34th CircleVancouver, WA 98682 USAhttp://www.usdigital.com/ Electric Motor and Drives2417 Hwy.29 N.Anderson, SC 29621http://www.emd-inc.com Owens Corning412 W Whitner StreetAnderson, SCwww.owenscorning.com/ Oconee Machine and Tool2319 Sandifer Blvd.Westminster, SC 29693 Acknowledgements

  21. Conclusions • What we learned • Questions • Mark GoettschGroup A

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