ECE 496 DC Motor DesignGroup A

December 01, 2003

Mark Goettsch

Introduction Project Objectives Team Construction Controls Results Web Development Conclusions Questions

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

Team Structure

Mark GoettschGroup Leader

Control Group Construction Group

Mark Goettsch

Jason Varner

Shawn Peterkin

Misty Maddox

Brad Peterson

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

Armature Plates

3/16” thick steel plates

2.5” diameter 17 total for

approximately 3” 8 slots, ½”

diameter

Shaft and Insulation

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

Stator 4” steel pipe

3.625” diameter

Adjustable air gap

Magnets 2 Pole ¼” thick Arc shaped 1.875 long 12 total 60 degrees of

separation between magnet pairs

Bearings and Support Steel baseplate

and support plates

Steel encoder plate

Pillow block bearings5/8” diameter

Commutator Brushes Helwig Carbon

Brushes Concave Radius 0.375x0.750x1.00

0

Copper over PVC 1.5” Long 8 segments

Construction Problems Machining time

Adjustable air gap

Securing magnets

Controls

Approach

Focus on Steady-State Response

Simplicity

QNIX and QMotor

Encoder US Digital

E3-1000-375-IHM-PKG3

Optical Encoder

1000 CPR

Wiring

Control Problems Working Computer

Learning QNIX and QMotor

Program quitting prematurely

ResultsBonus 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

Web Development

Acknowledgements US Digital Corporation

11100 NE 34th CircleVancouver, WA 98682 USAhttp://www.usdigital.com/

Electric Motor and Drives

2417 Hwy.29 N.Anderson, SC 29621http://www.emd-inc.com

Owens Corning

412 W Whitner StreetAnderson, SCwww.owenscorning.com/

Oconee Machine and Tool

2319 Sandifer Blvd.Westminster, SC 29693

Conclusions What we learned

Questions

Mark GoettschGroup A