Getting a silicon steel backplate (or several thinner ones, to reduce eddy currents) for the stator PCB laser cut shouldn't add much cost or complexity, but may greatly improve the magnetic flux density produced by the stator. Anything you can do to reduce the air gap between the rotor and stator will also improve performance. It may also be advantageous to use a laser-cut polycarbonate or FR4 rotor to improve balance and and tighten your tolerances (parallelism, coplanarity of magnet surfaces and concentricity especially). I would also consider using wedge-shaped magnets, assuming you can find a low-cost source.
can you please help me with my design? I also designed a PCB motor with a 120mm diameter 6 coil 2 layer and 3 phase delta connection but after assembling it with the rotor and the magnets that can't move after given supply with the BLDC controller.
try bearing ball pure dc mhd motor (bearings are the brushes, and the only thing that moves, and any rotor rides on top of the bearing balls, bearing balls should be possibly non-ferromagnetic, like tungsten metal balls). no coils, just radial current over the bearing balls over a vertical ring magnet. the motor is the bearing itself, no separate bearing. more bearing balls radially, the longer the L measurement and the more torque the motor has for the same current, F=ILB or torque=ILBr, also the radius of the motor affects in the same way, both larger the better.
Great job @365 Robots, Would you share more details on the PCB design? Did you try multi layer like 8 or more layers in comparison to 2 layer PCB? Would love to see a video explaining the PCD coil design if possible.
I only tried 2 layer pcbs for now. For the latest Video I attempted to stack multiple thin 2 layer PCBs together. This resulted in a decent torque increase. Sadly never got to measure the difference in torque on those designs.
Looking better and better! What are you doing for the axial magnetic field? I saw your one rotor with magnets... do you have some magnetic shunt plate on the other side of the coil? Or did I miss it and you have two magnetic rotors on either side of the coil pcb? Also, take a look into halbach arrays for the magnets. You can double the magnetic field on one side of your rotor by doing it. It might not be possable with your current arrangement... maybe a ferrous plate to back up the magnets on the non coil side?
I actually would love to stack another PCB Stator on top of the rotor. This way there is no need for shaping the magnetic field since ist can be used with the second stator as well. Adding a shut plate is a good idea. I will look into this in the future, thanks!
Have you tried to make this same design by hand? I was thinking of getting an electrolysis kit and building up my own multilayer boards. Maybe start with a thin sheet of fiberglass and then use solder mask between layers. This probably sounds nuts, but then again, I might just be crazy.
Great job, @365 Robots!! Can you tell me what kind of software you are configuring, and also what kind of ESC board do you use? I will be very grateful, I am just doing a similar project now and there are difficulties in connecting.
I am sure you have never heard of an induction motor. Or have you? My PCB motor uses induction and NO magnets at all and it's even thinner than your design.
Getting a silicon steel backplate (or several thinner ones, to reduce eddy currents) for the stator PCB laser cut shouldn't add much cost or complexity, but may greatly improve the magnetic flux density produced by the stator. Anything you can do to reduce the air gap between the rotor and stator will also improve performance. It may also be advantageous to use a laser-cut polycarbonate or FR4 rotor to improve balance and and tighten your tolerances (parallelism, coplanarity of magnet surfaces and concentricity especially). I would also consider using wedge-shaped magnets, assuming you can find a low-cost source.
Could you explain why a steel backplate would improve flux?
Which Software did u use for designing the electrical part of the motor stator?
Love it 👍🏻
I am making a sensored/sensorless foc esc and would love to evaluate the efficiency and performance
can you please help me with my design? I also designed a PCB motor with a 120mm diameter 6 coil 2 layer and 3 phase delta connection but after assembling it with the rotor and the magnets that can't move after given supply with the BLDC controller.
try bearing ball pure dc mhd motor (bearings are the brushes, and the only thing that moves, and any rotor rides on top of the bearing balls, bearing balls should be possibly non-ferromagnetic, like tungsten metal balls). no coils, just radial current over the bearing balls over a vertical ring magnet. the motor is the bearing itself, no separate bearing. more bearing balls radially, the longer the L measurement and the more torque the motor has for the same current, F=ILB or torque=ILBr, also the radius of the motor affects in the same way, both larger the better.
I think that you maybe can use cnc mill to make the plastic mover
Perhaps an iron core in form of Iron Foil? Also, can the coils be stackable?
Great job @365 Robots, Would you share more details on the PCB design? Did you try multi layer like 8 or more layers in comparison to 2 layer PCB? Would love to see a video explaining the PCD coil design if possible.
I only tried 2 layer pcbs for now. For the latest Video I attempted to stack multiple thin 2 layer PCBs together. This resulted in a decent torque increase. Sadly never got to measure the difference in torque on those designs.
Looking better and better!
What are you doing for the axial magnetic field? I saw your one rotor with magnets... do you have some magnetic shunt plate on the other side of the coil?
Or did I miss it and you have two magnetic rotors on either side of the coil pcb?
Also, take a look into halbach arrays for the magnets. You can double the magnetic field on one side of your rotor by doing it.
It might not be possable with your current arrangement... maybe a ferrous plate to back up the magnets on the non coil side?
I actually would love to stack another PCB Stator on top of the rotor. This way there is no need for shaping the magnetic field since ist can be used with the second stator as well.
Adding a shut plate is a good idea. I will look into this in the future, thanks!
Have you tried to make this same design by hand? I was thinking of getting an electrolysis kit and building up my own multilayer boards. Maybe start with a thin sheet of fiberglass and then use solder mask between layers. This probably sounds nuts, but then again, I might just be crazy.
Pcb way is great and all but you vould hace goten a 0.6mm or 0.4mm pcb at jlcpcb for just 2$
Great job, @365 Robots!! Can you tell me what kind of software you are configuring, and also what kind of ESC board do you use? I will be very grateful, I am just doing a similar project now and there are difficulties in connecting.
у тебя всё получится!!🥺💖
Oh you are going for FOC? Good luck!
That dev board can do FOC already with the SimpleFOC library! (does need an external encoder though)
Can you stack multiple PCB motors for more torque?
If I pay money can you send pcb board the same showing in video
Can i hire you as a designer for a product?
I am sure you have never heard of an induction motor. Or have you?
My PCB motor uses induction and NO magnets at all and it's even thinner than your design.
Can you share your email id I want to design such pcb
Not really, But feel free to ask in the comments. Everybody else will probably like to hear the answer as well!
Which software you use to design..