To understand how to make an electric motor with your own hands, you need to remember how it works and how it works.
If you follow the instructions step by step, it is not so difficult to make an electric motor yourself. The motor will serve for your projects.
The cost of manufacturing an electric motor will be minimal, since you can make an electric motor with your own hands using available materials.
The process of converting into a generator
The sequence of actions is as follows:
- The rotor is removed after removing the cover;
- The same stator windings remain; rewinding is not carried out;
- In order for it to become prefabricated, as opposed to its original solid state, it must be ground down to a predetermined size;
- A steel cup five millimeters thick is pressed onto the rotor;
- One of the most difficult operations is marking, which is carried out in order to glue the magnetic elements to the rotor according to the template. The dimension is individually selected for each engine unit;
- Magnetic elements made of neodymium are glued with superglue and additionally reinforced with a nylon filament mesh;
- Everything is wrapped with tape and formwork is carried out to seal it, and then filled with epoxy;
- Flowing down, the resin hardens, after which the tape must be removed;
- The rotor is driven into the generator part with all precautions so that the rotor “stands up” and does not “fly” into the stator due to the force of the magnets;
- The structure is assembled and closed with a lid;
- The functionality is checked using a drill.
Nuances of the rewinding process
Asynchronous operation of the motor allows it to maintain a constant frequency at which the rotor part rotates, even under different loads. If we talk about the principle of rewinding electric motors, then it is common in terms of execution technology. But individual nuances may vary.
It is best to take a failed device to a workshop, but in some cases it turns out that it is preferable to rewind the engine at home. Only on the condition that you still have certain skills in this matter, despite the relative ease of the process.
For engines there are two types of winding:
- Rotor part;
- Stator.
Taking into account the differences in the size of devices and their design, you can use generalized instructions for rewinding with visual photographs and a descriptive part.
Buy or make it yourself?
Buying a wheel motor is easier and more reliable. You don't have to be super-powered to make it and wonder if it will work after all the hours and effort put in. You can do it yourself if you have the necessary equipment and experience working with electronics.
Which option is more profitable depends on what you value more. If your time is valuable to you, choose and order MK with the characteristics you need from us. But if you want to experiment and make a motor-wheel of your own production, you can take a risk.
In the previous article, we shared a story from the lives of our customers - about renting an electric bike for their wife.
Basic provisions of the instructions
Once a breakdown is detected, the engine must initially be removed from the device.
Further work is carried out in the following sequence:
- The wire parameters and the total number of turns of the coil are determined during the inspection of the motor part;
- The most intact section of the winding fragment is cleaned;
- Carbon deposits are removed using a solvent or firing;
- The protruding upper part of the installation is cut off with an appropriate tool, depending on the cross-sectional area of the wire. Then it is decomposed into separate wires in order to be able to find out the number of turns;
- All detected irregularities on the surface of the iron where the winding was wound must be completely cleaned to make the surface smooth. Otherwise, a new breakout will not be long in coming;
- The cross-section of the new wire must be identical to the old one or as close as possible to it;
- A template is made from cardboard corresponding to the size of the iron on which the winding is carried out. When winding, a special machine is used.
Why do you need a soft start?
Smooth starting of an electric motor makes it possible to reduce the noticeable shortcomings of electric machines.
Besides:
- Repair costs are reduced, since any starting current always overheats the winding, thereby reducing the overall service life of the machine;
- There are practically no jerks, which has a good effect on reducing the wear of gears in transmission mechanisms, as well as the possibility of water hammer in the network when supplying fluid;
- Electrical energy consumption is greatly reduced, since direct starting requires a considerable amount of electrical energy. You need to know that the possibility of voltage sags in cases of power limitation in the network can negatively affect each of the connected devices;
- The overall cost of switching equipment is significantly reduced. Technical electrical devices for drives with an asynchronous operating principle are selected with a sufficient power reserve. The presence of a smooth descent makes it possible to connect more budget protection and switching devices.
The presence of acceleration after a soft start contributes to a significant expansion of the applied scope of asynchronous electric motors.
How to make an electric motor for a bicycle?
Of course, it’s easier and more reliable to buy a ready-made electric motor and install it on a bicycle. But if you are into electric DIY, you can build a direct drive wheel motor with your own hands. An inverter motor from an LG direct-drive washing machine is suitable for this. Finding it on the secondary market is a simple task, but it is much more difficult to adapt the purchased engine to a wheel motor.
The power of such a motor depends on the capacity of the washing machine. LG produces models with tank capacity from 3 to 12 kg, with electric motor power from 300 to 1000 W. But choosing an electric motor of suitable power is only the first and simplest step. Next, it will be converted into a motor-wheel using a step bearing and a mounting disk.
Carrying out the armature winding
To wind the armature of an electric motor, a copper wire with a large cross-section is required. An option is used with a non-insulated wire with a rectangular cross-section and an insulated wire with a round cross-section.
In the first case, the wire is intended for power starters with the ability to carry currents of six hundred Amperes or more.
- Insulated wire is used when winding low power starters.
- The winding is single-turn, consisting of a certain number of conductors.
- They are laid in loops in the core. One loop - one turn. A bandage on both sides of the exits beyond the core secures parts of the winding.
Application area
The most common use of generator sets with a squirrel cage rotor. They are inexpensive and require virtually no maintenance. Devices equipped with starting capacitors have decent efficiency indicators.
Asynchronous alternators are often used as an autonomous or backup power source. Portable gasoline generators work with them, they are used for powerful mobile and stationary diesel generators.
Alternators with three-phase windings reliably start a three-phase electric motor, therefore they are often used in industrial power plants. They can also power equipment in single-phase networks. The two-phase mode allows you to save fuel on the internal combustion engine, since the unused windings are in idle mode.
The scope of application is quite extensive:
- transport industry;
- Agriculture;
- household sphere;
- medical institutions;
Asynchronous alternators are convenient for the construction of local wind and hydraulic power plants.
Photo of a homemade electric motor
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