1. ECE 496 DC Motor Design Group A December 01, 2003Mark Goettsch

2. Introduction Project Objectives Team Construction Controls Results Web Development Conclusions Questions

3. 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

4. Team Structure Mark Goettsch Group Leader Control Group Shawn Peterkin Misty Maddox Brad Peterson Construction Group Mark Goettsch Jason Varner

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

6. Armature Plates 3/16” thick steel plates 2.5” diameter 17 total for approximately 3” 8 slots, ½” diameter

7. 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

8. Stator 4” steel pipe 3.625” diameter Adjustable air gap

9. Magnets 2 Pole ¼” thick Arc shaped 1.875 long 12 total 60 degrees of separation between magnet pairs

10. Bearings and Support Steel baseplate and support plates Steel encoder plate Pillow block bearings 5/8” diameter

11. Commutator Brushes Helwig Carbon Brushes Concave Radius 0.375x0.750x1.000 Copper over PVC 1.5” Long 8 segments

12. Construction Problems Machining time Adjustable air gap Securing magnets

13. Controls

14. Approach Focus on Steady-State Response Simplicity QNIX and QMotor

15. Encoder US Digital E3-1000-375-IHM-PKG3 E3-1000-375-IHM-PKG3 Optical Encoder 1000 CPR

16. Wiring

17. Control Problems Working Computer Learning QNIX and QMotor Program quitting prematurely

18. Results Bonus 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

19. Web Development

20. Acknowledgements US Digital Corporation 11100 NE 34th Circle Vancouver, WA 98682 USA http://www.usdigital.com/ http://www.usdigital.com/ Electric Motor and Drives 2417 Hwy.29 N. Anderson, SC 29621 http://www.emd-inc.com http://www.emd-inc.com Owens Corning 412 W Whitner Street Anderson, SC www.owenscorning.com/ www.owenscorning.com/ Oconee Machine and Tool 2319 Sandifer Blvd. Westminster, SC 29693

21. Conclusions What we learned Questions Mark Goettsch Group A