Faculty Project Description for Brushless DC Motor Project

Project Description
The brushless DC motor project has been used for at least two years in a first-s
emester
introduction to electrical engineering (EE) course. More than 125 first-year EE
students have
successfully built the project during that time. The simple-to-construct motor k
its provide
exposure to elementary circuits, magnetics, power electronics, and feedback syst
ems.
Feedback signals are generated using magnetic and optical sensors. The feedback
signal
causes an electromechanical reed switch or a power transistor to actuate an elec
tromagnetic
coil. Project benefits are an animated, physical manifestation of electrical eng
ineering and a
recruiting tool for future students. Assessment results indicate a high degree o
f student
satisfaction with the project.
Educational objectives of the project are to gain an understanding of the operat
ion and
application of brushless DC motors, particularly in transportation systems; to c
omprehend the
electrical, magnetic, and mechanical principles of operation of the brushless DC
motor; to
correlate the physical system components and layout with their abstract schemati
c
representation; to use physical sensors as feedback elements; and to compare the
use of an
operationally visible mechanical reed switch as a coil commutator with the use o
f a solid state
power transistor.
An assignment to analyze the potential impact of personal electric vehicles on e
nergy use and
carbon dioxide emissions is included to illustrate a real-world application and
its benefit to
society. This assignment depends on at least two lecture periods for introductio
n and
clarification. The students write a final report that: defines the problem, show
s construction and
final stage pictures of their motor, presents their analysis results, and draws
conclusions. This
report is a major outside effort for the students. You may want them to work in
pairs to reduce
the work. Make sure a digital camera is available during motor construction or t
hat some
students can bring theirs and share.
A schematic of the system showing all electrical components is shown in Figure 1
. In this
1.5V
1.5V
1.5V
1.5V
TIP106 Reed
switch
1N4001
X
3121E
SW1
k
OPB831W55
Optical switch
SW2
SW1 and SW2 are
conceptual only.
Implemented as wire
hook-ups on breadboard.
Hall-effect
switch
k
COIL
Figure 1. Schematic of brushless DC motor
system, the position of the rotor may be sensed by a Hall-effect sensor switch,
a slotted optical
switch mechanically configured as a rotary encoder, or a reed switch. The Hall s
ensor or the
optical switch signal drives the base of a Darlington PNP transistor. The transi
stor operates as
a switch to energize the coil whenever a rotor permanent magnet is facing the co
il.
Alternatively, the reed switch may be used to combine the sensor and coil switch
ing functions.
The diode allows the coil current to circulate during times that the coil is dis
connected from the
battery supply. This reduces voltage stress on the transistor and reed switch. T
he
freewheeling diode provides opportunity for further exploration by students.
The motor is built in two laboratory
stages. An unassembled motor kit is
shown in Figure 2. Although students
build their own individual motors, they
work in pairs to assist each other in
assembly.
The first operational stage, built in the
first-week laboratory, uses a mechanical
reed switch to commutate the
electromagnetic coil. Students can see
the reed switch actuate as they move the
rotor permanent magnets. During the
second-week laboratory, the reed switch
is replaced with a bipolar junction
transistor (BJT). The remainder of the
construction is completed and a fully assembled motor is shown in Figure 3. The
transition
from the mechanical reed switch to the solid state transistor switch effectively
introduces the
concepts of current flow and transistor switching. The students physical understa
nding of
switch operation provides a basis for understanding transistor operation as a sw
itch. It is
rewarding when first-year EE students comprehend the functional operation of the
transistor
as a switch. The concept of magnetic field attraction and repulsion is also obse
rved.
Having optical and Hall-effect feedback
available invariably raises the student
question, Which is better? This yields a
great opportunity to discuss their relative
merits and applications. Students also can
see the effects of inductive switching by
removing the freewheeling diode from the
circuit and seeing the reed switch arc as it
operates. Students may observe the switch
voltage on an oscilloscope with and without
the freewheeling diode in the circuit.
Students may measure the speed of their
motor using a stroboscope or an
oscilloscope attached to the rotor position
signal. If these instruments are available,
speed measurement is a very satisfying
conclusion to the laboratory. Some students
Figure 2. Unassembled motor kit

Figure 3. Fully-assembled final stage motor

modified their motors (e.g., by adjusting encoder phasing or by adjusting the po
sition of Hall
sensor) to demonstrate the effects on motor speed.
The parts list for the project is shown in Table 1. Cost per kit has been $50 fo
r the past two
years. The supplier at http://www.simplemotor.com/ has been used for all items e
xcept those
with an asterisk.
OPB831W or eq. Slotted optical switch
A3121E Hall-effect switch
e.g., Yaskawa R24U Reed switch (1A, 50V)
TIP106 PNP Darlington transistor (2A, 20V)
1N4001 Diode (2A)
270O, 10k.
¼W resistors
50 ft, 27 ga. magnet wire
4 nail for magnet wire coil
4 permanent magnets 0.5 dia. discs
5" x 6" press-board
Pre-cut 7/8 round PVC pipe
Pre-cut 5/8 square PVC pipe rotor core
7/8 PVC endcaps
Opaque optointerrupter disk 1.3 dia.
Pushpin
T-pin
Sequins
Adhesive felt
Rubber cab to protect sharp end of t-pin
Super glue
4 AA battery holder
¼ round dowel
1.25 long square (3/8 sides) wooden stand
24 ga. jumper wire*
Male header pins*
Female headers*
TO-220 heat sink*
Heat sink grease*
2 x3 breadboard*
Useful tools and equipment:
Safety glasses, solder iron, solder, wire cutters, wire stripper, steel cutter,
sandpaper,
electrical tape

A complete set of motor assembly instructions follows. This is provided to the s

tudents. The
students work in pairs to help each other build their motors.
Assembly Instructions:
Brushless DC Motor

Instructions (read and understand each step completely

before acting!)
1.
Insert the T-pin into one of the end caps.
2.
Insert the rotor core into the same cap as shown below.
Carefully apply some pressure (avoid poking yourself
with the sharp T-pin) to push the rotor core
approximately 1/2" (10-12mm) into the cap.
3.
Insert the round wooden dowel into rotor core tube.
4.
Insert the pushpin into the other cap.
5.
Complete rotor assembly as shown. Carefully push the
caps towards each other until they cannot move any
more. The T-pin must be secured firmly. This process
may require some strength. Be careful not to bend the
T-pin or poke yourself.
6.
Carefully open the super-glue tube. Make sure you are working over a protected
surface. Glue the magnets to the flat surfaces of the rotor core with the letter
S
facing out. Straighten the T-pin if necessary. You will need to press the magnet
s
onto the rotor for at least 30 seconds to allow the glue to adhere.
7.
Cut out the disk.
Poke a hole in the center, which is
marked by a cross. Apply some glue to
the middle of the disk and glue it to the
cap with a shorter axle (with the
pushpin). Slide two sequins as shown
below. The sequins act as a spacer
between the disk and the stand and
work better if their convex surfaces face
outwards.
8.
Insert the rotor into the stands marked with blue
and silver stars as shown below. Hold the stands
and test to see if rotor spins freely. Make final
adjustments to the T-pin if necessary.
9.
Position the stand with the blue star on the board.
While covering the corresponding star completely,
align the marks on the stand with the line on the
board as shown. Keep in mind that super glue bonds
instantly. Glue the blue star stand to the board.
10.After letting the glue set, insert the
rotor into the stand marked with the
blue star.
Note that the star's position and the
marks are approximate. You may
need to move the silver star stand
slightly to achieve the lowest
rotational friction. Leave a gap of
about 1/16" (1/32", or 0.8mm on
each side) between the rotor and
the stands.

Glue the silver star stand to the

board. Test again to see if the rotor
spins freely.

Carefully use steel cutters (not wire

cutters) to trim the off the sharp end
of the T-pin (shield the free, sharp
end to keep it from flying away during
trimming). Or, secure the rubber end cap on
the sharp end of the T-pin.
11.Insert the nail into the stand with the green
star. Apply glue as shown.
12.Cut two 8" lengths of wire from the
magnet wire spool. These will be used
later for connecting the reed switch. Use
the rest of the spool of wire to wrap
around the area between the tape and
the head of the nail. Keep the coil turns
relatively tight and always wrap in the
same direction.
Tape the end and beginning of the
wire using the same tape and
leaving open ends of wire about 6"
long. Remove about ¼ to ½ of
the wire ends insulation with
sandpaper.

Both leads ends

must be more
than 5 long
13.Solder the two coil leads to the short end of two
male header pins. You may have more success at
soldering if you work with a partner. Ask for
instructor help if you have trouble.
14.Position the coil stand on the board as shown. Turn the rotor slowly to find
the
rotor magnet that comes closest to the coil head. Position the stand so there is
a
1/16" (1.5mm)
gap between
the coil head
and the closest
magnet on the
rotor. You may
wish to mark
this position on
the board to
remember it
before gluing.
Glue the stand
onto the board
in this position.
15. Attach the green self-sticking felt pad to the reed switch stand as shown.
This soft pad decreases the reed switch vibration thus decreasing the sound
it generates.
16. Sand the wire ends of the
two 8 lengths of wire you
cut earlier to remove the
insulation. Clean about 1"
to 1.5 (4cm) on one end
and ¼ to ½ on the other end of each wire piece. Be careful not to break the reed
switch, it is very fragile. Wind longer bare ends tightly around outside contact
s of
the reed switch as shown. Solder the wires onto the reed switch.
17.Twist the wires as shown.
Make sure the reed switch is
kept securely in the position
shown by the twists of wire
on the opposite side of the
stand.
18.Make sure the reed switch is oriented as shown in step 15. Solder the ends of
the
reed switch leads to the short ends of two male header pins.
19.Position the reed switch holder on the
board. It should be located at a distance
of about 1/8" (3mm) from the closest
magnet. Check the rotation of the rotor
to make sure that it does not hit the
reed switch. The three slots cut into the
stand must line up with the rotor
magnets.
IMPORTANT: The most sensitive part of the reed
switch is not in the middle of it, but more to the side
as shown to the right. You should hear a clicking
sound when each magnet passes by the reed switch.
Move the reed switch a little closer to the magnets
until all four can turn the reed switch on.

Make sure the three slots cut into the stand line up with the rotor magnets.
Glue the reed switch holder to the board.
20.Tin the battery holder leads with
solder. Solder the battery holder
leads to the short ends of two
male header pins. Attach the
battery holder to the board in the
position shown.
You may have more success in
soldering if you work with a partner.

21.Set the board aside.

Tin the three colored leads with solder. Solder the
three colored leads to the pins of three-pin female
header strip. This is the most difficult solder step.
Ask for help if you need it!
The color order is important!
Red=right, black=center, blue=left.
Tin the other end of these leads with solder.

22.Get two, two-position female parts. Cut

four 10 leads from the wire in your kit.
Tin the leads with solder. Solder leads to
each of the four header pins.
FINISHED SOLDERING!
Positive
battery
Coil
Negative
battery
23. Tape the 2 x3 breadboard onto the motor base board in the
position shown. You should have three pairs of male header
pins from the battery pack, the coil and the reed switch.
Connect the circuit using the header pins and the breadboard.
Make sure the wires cannot get wrapped onto the rotor. Insert
batteries to verify operation. You may need to reverse the coil.
1.5V
1.5V
1.5V
1.5V
Coil
Reed
switch
COIL
Reed
switch
24.Insert the Hall-effect sensor into the three-pin
female header strip. Holding the sensor with the
printed side up, the left side should insert into the
red-leaded jack. Use needle-nose pliers to carefully
bend the Hall-effect sensor to a 90° angle with the
printed side of the sensor facing outward.
25.(Optional: Smear a dab of heat-conducting grease to the metallic
tab-side of the TIP106 transistor.) Attach the transistor to the
heat sink fin using the small bolt and nut. Use needle-nose pliers
to bend the leads as shown.
26.Insert the Hall-effect assembly onto the reed-
switch stand. The printed-side of the sensor
should face the rotor magnets. It needs to be
close, but not touching the rotor magnets.
27.Connect the Hall-effect sensed /
transistor-switched circuit. You will need
to make two jumper wires. If you use
stranded wire to make jumpers,
1.5V
then tin the leads with solder to
make them easier to plug into the

10k
breadboard. One connects the 1.5V

emitter
TIP-106 to the Hall switch (see
base
TIP106
1.5V
circuit diagram on right), the other
jumper wire connects the TIP-106
collector
to the negative battery supply.
Hall-effect 1.5V
switch
Try to get the Hall switch chip as
close to the rotor magnets without
touching them.
Verify operation!

3121E
Black
Red Blue
COIL
10k resistor
Hall switch Red
Hall switch Black
Jumper wires
Hall switch Blue
Locate the optointerrupter pins as shown on the following picture. It is very im
portant to
identify all four pins properly. Wrong connection in the circuit will destroy th
e
optointerrupter. There are no spares of this part. Insert the two pairs of long-
leaded
female header strips onto each pair (Emitter and Sensor) of opto pins making sur
e they
are not touching each other.

28.Glue the opto to the square wooden stand aligned with

the guidelines on the stand. The Sensor side should be
attached to the stand.
29.Position the optointerrupter stand on the board as
shown in the picture. If you rotate the rotor, the disk
blades should be in the middle of the slot as deep as
possible without hitting the optointerrupter. Glue the
stand to the board. Wait for the glue to dry. You will
need to experiment with it to find the best position of
the disk to provide a good start and the best speed.
30.Connect the Hall-effect sensed / transistor-switched circuit. Verify operatio
n!
31.
Clean up the wiring. Arrange breadboard connections so you can demonstrate your
circuit in its three modes of operation.
32. If a tachometer is available, use it to measure the speed of your rotor for
its
different modes of operation.