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DC Motor Project Description

This document outlines an assignment to design, build, and test a DC motor. It is split into two parts - Part A involves computing design aspects in Excel and MATLAB, and Part B involves physically constructing the motor. Key requirements for the motor are specified, including operating on DC power below 30V and 5A, having 3-8 coils, and being able to overcome a minimum torque of 0.000845 Nm. Materials for construction are made available. Testing will involve measuring the motor's speed and torque output while coupled to a generator. A report must be submitted documenting the design, construction, and test results.

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Mohammad Raheel
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113 views

DC Motor Project Description

This document outlines an assignment to design, build, and test a DC motor. It is split into two parts - Part A involves computing design aspects in Excel and MATLAB, and Part B involves physically constructing the motor. Key requirements for the motor are specified, including operating on DC power below 30V and 5A, having 3-8 coils, and being able to overcome a minimum torque of 0.000845 Nm. Materials for construction are made available. Testing will involve measuring the motor's speed and torque output while coupled to a generator. A report must be submitted documenting the design, construction, and test results.

Uploaded by

Mohammad Raheel
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Electromagnetics and Machines

DC Motor Building Assignment 20%


Assignment Description
The purpose of this assignment is to give you practical experience designing and building a DC
motor. The DC motor assignment consists of two parts. The first is a computing design task that will help
you design and simulate your DC motor prior to construction. The results of this analysis will be used to
make important design decisions for your actual motor build. The second part is to construct a DC motor
that will be demonstrated in Week 13.
.

Knowledge Requirements
Before you are able to complete your DC Motor Assignment you will need to know:
• DC motor parameters and how these affect motor performance.
• How DC motors are physically constructed.
• How to test DC motors to assess performance.
• How to use Excel and MATLAB.
Part A - Computing

1 Assignment Task
Your group is required to submit a motor proposal in the form of a one page outline, an Excel workbook,
and a MATLAB script. This outline is to be submitted as a ‘tender’ document which goes out to the client.

Contained in the one-page outline should be:

• Details on your motor size and structure.


• Summary of calculations including, rotor size, number of turns, number of coils, type of motor,
current and voltage specifications.
• You should also include the operating torque and speed that your motor should generate, the
expected mechanical output power, and theoretical efficiency. List any sources of loss and the factor
that you have allowed for to ensure that your expected results align with the targets listed in the
CRA.

In the Excel sheet:


• You are expected to use the Excel sheet to find:
o Motor Constant K.
o Resistance of the armature.
o Expected speed of the motor in rpm (using terminal voltage).
o Expected torque generated of the motor in Nm (using armature current).
o Ideal mechanical power out.
o Expected mechanical power out (include factor for inefficiencies).
• Ensure your sheet is clear, and well-presented and includes at least one example of data validation,
custom cell formatting and static cell references.

In the MATLAB script:


• You are expected to use the MATLAB script to find:
o The time to accelerate the motor from standstill to maximum speed; minimum and
maximum currents including an applied torque to the motor shaft
o Multiple plots of the speed torque characteristic for the different field magnetic flux
densities created by the different permanent magnets
• Ensure your script file is well presented (including useful comments that make your script easy to
understand) and that it states any assumptions
• Ensure that you have at least one example of the MATLAB functions: input, disp, sprintf.
• Ensure that you have demonstrated: multiple lines on a single plot, multiple plots on a single figure,
fully formatted graphs including titles, axes labels, colours and legends where appropriate.
Part B – Motor

1 Assignment Task
You are required to construct a brushed commutated DC motor to drive a load that will be simulated by a
loaded generator placed on the output shaft of your motor. You may use any readily available materials.

We will provide a DC motor construction kit which, if used correctly, will provide you with
all of the parts required to make a functional DC motor. You should look in to ways that you can improve
your motor, for example, by improving the quality of your commutator and/or bushes, improving the
strength of your frame, and by optimising the position of the magnets. This is not essential, but will
demonstrate that you have investigated ways to improve the performance of your motor.

Your magnet selection and wire selection will be based on the results of the calculations you perform in your
computer labs and the following criteria.

The motor MUST be supplied by Direct Current (DC):

• The motor must be brushed/commutated,


• The motor must be supplied by a DC source (Battery, Laboratory Power supply, etc, no active
controllers),
• The motor must have a minimum of 3 coils, and a maximum of 8 and must be lap wound,
• The motor must use a maximum of 45 m wire,
• The motor may NOT draw more than 5A, and must operate at less than 30V. The no-load speed
must be limited to 2000 rpm for safety reasons,
• Your motor MUST be able to overcome the internal resistance to rotation of the
dynamometer/generator which is used for testing purpose. This resistance has been measured to be
0.000845 Nm,
• The motor ideally should start without any external assistance.
The field MUST be supplied by two permanent magnets:
• A set of magnets will be available from the store on S-Block, level 9,

The motor MUST be entirely constructed by you:


• You may get ideas from other, commercially available DC machines, however NO parts
must be transferred to your own design
• NO kits of any kind should be used in the motor construction (this includes mechano / lego /
jaycar kits), except for the QUT provided kit
• Commercial brushes, and commutators CANNOT be bought, but home made alternatives to
those supplied in the kit can be used

1.1 Collection of Motor Parts


All parts are collected from the store on level 9 of S-Block. To ensure access to materials is fair to all
groups,
a voucher system will be used to prevent groups from doubling up on materials. The vouchers can be
found at the end of this document.
Motor Kit

This can be collected once you have formed your group and have your group’s voucher signed by
your computer lab demonstrator.
Magnets, Wire and Laminations

These can be collected once you have completed your Excel calculations that will determine your
magnet selection, choice of wire, and type of laminations. NOTE: You will receive your wire on a spool.
These
spools must be returned to the store in level 9 before your demonstration day (your proof of return
voucher will be checked during the demonstration). They must be returned empty, with all wire removed.
1.2 Generator Information
A loaded generator will be coupled to your motor during the test. This will be fitted with a shaft encoder
that will monitor the output speed of your motor.

1.3 Knowledge and Application


An oral examination will also be performed at the time of test and demonstration, relating to the operation
and design of the motor, directed at individual group members.

The decisions made in building your motor, including material types, winding methodology, number of
commutator plates, number of brushes, radius and length of motor, and operational speed/torque
characteristics will ultimately determine its use. Your group is to design the motor for a specific application,
such as a traction motor, EV drive motor, conveyor belt motor, etc. Your design may be a ‘scaled’ version of
the real application, however must be constructed to the same considerations that would exist in the real
situation. Ensure that your report reflects this application throughout, and that your design choices support
the final application.

The criteria for the physical and oral examination can be found on Blackboard.

1.4 Construction
1.5 Testing

2 Report and Documentation


Only one report is to be submitted for each group of students. The report should consist of two sections,
one for computing and one for the motor itself. The design process should reference the calculations
performed in the computing labs. The report should include (however is not limited to);

Part A: Design Phase:


• Calculation, planning, materials selection, etc..
• Excel Spread Sheet analysis of field and armature windings.
• Expected speed and torque graphs.
• Acceleration graphs from MATLAB.
Part B: Construction and Testing:

• Construction iterations if any.


• Test procedures at various stages.
• Quality assurance for winding insulation.
• Results of speed, power input, power output, efficiency, operating characteristics and output
torque.

Review Phase:

• Work breakdown, reflective analysis of the phases, analysis of how concurrent engineering
modified your thought process and ultimately the outcome, recommendations, and
future improvements.

You may use these headings as a guide, or organise the report as you see fit, it is always refreshing to read
unique reports and it certainly puts the marker in a much better state of mind when considering your report.

You may write as much or as little as you see fit, however please note that conciseness is listed on the
criteria sheet. Anything over 30 pages may be considered too extensive, anything under 10 might not
contain enough depth. Approximately 4000 to 6000 words should be sufficient. Use this as a guide only.

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