Brushless Motors: January 2008 Wayne Rademacher

Brushless Motors
January 2008
Wayne Rademacher
Motor selection info.

Watts per pound of airplane weight.
100w/lbs = trainer/sport 150w/lbs = 3D aerobatics 200w/lbs = extreme
Watts = volts * current

7.4v * 10amps = 74watts 11.1v * 25amps = 277watts 22v * 50amps = 1110watts
Ex. 16oz sport airplane = 100w motor 746watts = 1 horse power

January 2008
Wayne Rademacher
Motor formulas
Efficiency: Motor Efficiency = Pout/Pin, Pout = (Vin - Iin * Rm) * (Iin - Io) Motor Kv: Kv = RPM / (Vin - Vloss), Vloss = Iin * Rm Motor RPM: RPM = Kv * (V - Vloss), Vloss = Iin * Rm Watts: Watts = V * Iin, Alternately P=IR (P = I x I x Rm) Stalled Motor: Istall = Vin / Rm Torque constant: Torque constant: Kt=Kb x 1.345, Kb = Voltage constant (Volt/1000 RPM) Torque Loss: Torque = Kt * (Iin - Io) Termination: Wye = the number of winds you have performed, Delta = divide the number of turns by 1.73 Watts per Horsepower: 1 horsepower = 746 watts Kv-Rpm constant: Kv * turns = motor constant, (ex. Kv=1090 * 32T ~= 35000 so, 35000/28T ~= 1250Kv)
January 2008
Wayne Rademacher
Motor formulas - Acronyms

Acronyms:
Rm = Resistance value of the motor, derived from the guage of wire used. Pout = Power Out of the Motor expressed in Watts Pin = Power In of the Motor expressed in Watts Vin = Voltage Into the Motor Iin = Current Into the Motor
Io = Noload Current of the Motor, derived from running a motor WOT without a prop at varying voltages. Io can be expressed with an associated Voltage and should be. Kv = K value or voltage constant, the expressed value where the rpm can be surmised by a given voltage. For a 2000 Kv motor an input voltage of 10V would net 20000RPM. Istall = The load current of a motor which is purposely stalled, hence not turning. Kt = Torque constant (oz-In/A) Kb = Voltage constant (Volt/1000 RPM)
January 2008
Wayne Rademacher
Misc. motor info.

PI*(dia./2)^2) = sectional area of wire ~ Delta > Star = .578 (.562 - .526) ~ Star > Delta = 1.73 (1.78 - 1.9) Doubling the number of winds halves Kv (rpm/volt) and doubles Kt (torque/Ampere), Doubling stator height halves Kv, doubles Kt and (roughly) doubles maximum power. Kv-Rpm Constant: Example: The 3008-32 motor has a Kv of 1090. If you take 1090 x 32 you get 34,880. If you look at the 3008-28 motor, it has a Kv of 1253. If you take 1253 x 28 you get 35,084. Based on these 2 numbers, you can see that the constant for the 3008 size motor is right arounf 35,000. If you take 35,000 and divie that by the number of turns, you will get the approximate Kv of the motor.
January 2008
Wayne Rademacher
Brushless motor construction

The basic 3-phase build
January 2008
Wayne Rademacher
Why build?

Fun Cheap Rewarding Build the perfect motor for your application.
January 2008
Wayne Rademacher
Electronic Gearing
Divide 360deg by number of magnets then divide by 3 phases.
This provides the degree of movement per step sequence.
6 cycle step sequences needed to complete 1 revolution of the magnetic field.
A to B / C to B / C to A / B to A / B to C / A to C
Examples: 10 magnet 360deg / 10 mag = 36deg || 36deg / 3 phase = 12deg (12deg / step) x 6 steps = 72deg. Sequence 360deg / 72deg = 5 or 5:1 gearing 14magnet 360deg / 14 mag = 25.71deg || 25.71deg / 3 phase = 8.57deg (8.57deg / step) x 6 steps = 51.42deg. Sequence 360deg / 51.42deg = 7 or 7:1 gearing January 2008
Wayne Rademacher
9-pole magnet options

9-pole stator basically two choices:
6 magnets (3:1 gearing)

High RPM (Kv), low torque Good for Helis and ducted fans
12 magnets (6:1 gearing)
Low RPM (Kv), high torque Larger propellers, 3D flying

Wayne Rademacher
January 2008
12-pole magnet options

12-pole stator four choices:
LRK or DLRK wind
10 magnets (5:1 gearing) Higher RPM (Kv), lower torque 14 magnets (7:1 gearing) Lower RPM (Kv), higher torque 8 magnets (4:1 gearing) Higher RPM (Kv), lower torque 16 magnets (8:1 gearing) Lower RPM (Kv), higher torque
Wayne Rademacher
ABC wind
January 2008
Wind techniques / options
9-pole stator can only be wound using ABC wind
ABC - ABCABCABC
12-pole stator can be wound either ABC, LRK or DLRK.

ABC ABCABCABCABC (easy, need more magnets) LRK A-b-C-a-B-c (high wrap count per tooth, less to wind) DLRK AabBCcaABbcC (low wrap count per tooth, more to wind
January 2008
Wayne Rademacher
12 stator pole wind types
January 2008
Wayne Rademacher
Star or Delta connection?
January 2008
Wayne Rademacher
Magnet polarity
January 2008
Wayne Rademacher
Magnet installation
January 2008
Wayne Rademacher
Check for shorts Solder wires
January 2008
Wayne Rademacher
9-pole stator ABC wind
January 2008
Wayne Rademacher
9 pole Star connection
January 2008
Wayne Rademacher
9 pole Delta Connection
January 2008
Wayne Rademacher
January 2008
Wayne Rademacher
Phase A of the ABC wind 12-pole, 8 or 16-magnets
January 2008
Wayne Rademacher
12 pole ABC Star Connection
January 2008
Wayne Rademacher
12 pole ABC Delta Connection
January 2008
Wayne Rademacher
Distributed LRK winding diagram for 10 or 14 magnet poles.
January 2008
Wayne Rademacher
Phase A, DLRK wind
January 2008
Wayne Rademacher
LRK or DLRK
January 2008
Wayne Rademacher
Resources:
www.innov8tivedesigns.com
Scorpion motors / kits Motor kits Motor kits Excellent source of information.
Wayne Rademacher
www.gobrushless.com
www.komodohobby.com
www.rcgroups.com
January 2008

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Brushless Motors

Motor selection info.

100w/lbs = trainer/sport 150w/lbs = 3D aerobatics 200w/lbs = extreme

Watts = volts * current

7.4v * 10amps = 74watts 11.1v * 25amps = 277watts 22v * 50amps = 1110watts

Ex. 16oz sport airplane = 100w motor 746watts = 1 horse power

Motor formulas - Acronyms

Misc. motor info.

Brushless motor construction

Divide 360deg by number of magnets then divide by 3 phases.

This provides the degree of movement per step sequence.

6 cycle step sequences needed to complete 1 revolution of the magnetic field.

9-pole magnet options

6 magnets (3:1 gearing)

12 magnets (6:1 gearing)

Low RPM (Kv), high torque Larger propellers, 3D flying

12-pole magnet options

Wind techniques / options

9-pole stator can only be wound using ABC wind

12-pole stator can be wound either ABC, LRK or DLRK.

12 stator pole wind types

Star or Delta connection?

Check for shorts Solder wires

9-pole stator ABC wind

9 pole Star connection

9 pole Delta Connection

Phase A of the ABC wind 12-pole, 8 or 16-magnets

12 pole ABC Star Connection

12 pole ABC Delta Connection

Distributed LRK winding diagram for 10 or 14 magnet poles.

Phase A, DLRK wind

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