как подключить кнопку, заменить щётки, проверить ротор

Как починить, ремонт

Ротор в отличие от статора, основным элементом которого является обмотка, имеет более сложную конструкцию. Кроме намотанных в пазы сердечника катушек, в его сборку входят подшипниковые узлы, коллектор, вентилятор и собственно сам вал. Это увеличивает количество вариантов неисправностей, а значит отремонтировать ротор несколько сложнее, чем статор.

Ремонт обмоток ротора

В следующем видео описан ремонт ротора по наиболее частой неисправности электрической части — повреждение обмотки. Автор кратко описывает последовательность операций ремонта обмоток ротора: от диагностики до самой перемотки и пропитки.

Важно: автор указывает на контрольную проверку приборами правильности выполнения каждой операции там, где это необходимо.

Ремонт коллектора

Дефект, который устраняется в следующем видео, а именно отрыв ламелей коллектора, при целых обмотках ротора встречается не так часто. Однако, автор с блеском выполняет его в домашних условиях. Вместо отсутствующих ламелей изготавливаются новые из медной проволоки методом холодной ковки.

После пайки и приклеивания ламелей, убираются слесарным путем все наплывы, и окончательная доводка поверхности коллектора производится оригинальным методом, предложенным автором. Далеко не всегда в домашних условиях найдется токарный станок, поэтому якорь собирается по месту своего прямого назначения (в болгарку), где вместо щеток устанавливается инструмент для обработки ламелей коллектора.

Он представляет собой подогнанные по размеру деревянные бруски, на которые прикрепляется шлифовальная шкурка. Усилие обработки создается затягиванием на определенную величину поджимающей брусок заглушки. Привод ротора осуществляется через шпиндель другой болгаркой. Таким образом, меняя несколько раз шлифовальную шкурку, добиваются идеально ровной и полированной поверхности коллектора после замены ламелей.

Замена крыльчатки вентилятора

В следующем видео на роторе разбита ступица металлической крыльчатки после попадания в нее постороннего предмета. Автор нашел выход из положения, собрав новую крыльчатку из поломанной и другой, взятой со сгоревшего ротора перфоратора. На самодельном приспособлении из дрели и тисков с крыльчатки из перфоратора (пластмассовая), насаженной на ротор, острым ножом были отрезаны лишние элементы, то есть осталась только ступица. Далее на ступицу была приклепана поврежденная крыльчатка. При вращении, с помощью привода, дрелью, опорой на подшипнике в тисках и напильника, на собранной новой крыльчатке было выставлено требуемое радиальное и торцевое биение.

Искрит ротор, причина, как исправить

Основные причины, вызывающие повышенное искрение во время работы болгарки.

• Износились щетки. Следует их заменить, иногда для достижения результата вместе со щеткодержателем и поджимающей пружиной.
• Обрывы, замыкания в обмотке ротора. Устранить сильное искрение поможет замена якоря или перемотка новой обмотки. В видео замена якоря и щеток создает нормальные условия для функционирования щеточно-коллекторного узла.

90000 Disassembling a Brushless Motor | Flite Test 90001 90002 90003 90004 P.S: Before disassembling the motor, if your item carries a warranty, opening and attempting your own repair, will void whatever warranty you have. 90005 90006 90007 90008 90009 90010 90008 90010 90008 The following article contains a short tips on disassembling the brushless motor. Brushless motor should run smoothly from the lowest to maximum throttle with minimum vibration. We could easily listen to the smooth running noise of the motor without mounting the prop.Crashes from major to minor ones might cause unexpected damage to the motor; causing a rough run and noise, bad vibration and / or even twitching / stuttering at the start of the motor or during lowest throttle. Often, you might be able to hear a clicking or scrubbing noise when you rotate the motor manually. This is caused by the surface contact between the stator and the permanent magnets on the rotor; scratch lines can be seen on the stator and the rotor. Damaged bearings and bent shaft are the primary cause of this phenomenon.However, if the bearings and / or the shaft are replaced immediately, the motor might be restored to normal. Sometimes the motor has already been damaged badly and the phenomenon still present even after replacing the bearings and shaft. 90010 90008 90010 90008 To start disassembling the motor, various tools are required. The safest method is to use the bench press tool, however in this article, the disassembly procedure is done using the tools as shown in the picture below. 90010 90008 90010 90008 90022 90010 90008 90010 90008 The first step involves in removing the circlip (E-ring), followed by the collar ring from the rear shaft using the pliers.90003 90004 Be cautious when removing the circlip because it might spring out. If you do not have any spares, do not lose it or bend it out of shape. 90005 90006 90010 90008 90033 90010 90008 90010 90008 The second step is to pull and remove the rotor (the bell) from the stator (the body). 90010 90008 90010 90008 90042 90010 90008 90010 90008 Notice that there are two bearings attached to the rear end and front end of the stator. The next step is to remove the bearings from the stator.Sometimes, the bearings are easy to remove, and some have a tight fit. Remove one of the bearings using barbeque skewer or any wooden stick to plug out the bearing from the stator. Usually, the front end bearing is easier to remove. 90010 90008 90010 90008 90051 90010 90008 90010 90008 90056 90010 90008 90010 90008 After you have managed to remove one of the bearings, use a pin punch tool to push the other bearing out from the stator. 90010 90008 90010 90008 90065 90010 90008 90010 90008 Place the stator on the plastic wire spool / solder bobbin and carefully tap the pin punch tool using the hammer until the bearing drops out from the stator.90010 90008 90010 90008 90074 90010 90008 90010 90008 90079 90010 90008 90010 90008 Now you can replace the old bearings with the new ones. You might use the pin punch tool to push the new bearings into place. 90003 90004 Just lightly tap to prevent any damage to the new bearings. 90005 90006 90010 90008 The next procedure is to remove the shaft from the rotor (the bell). Use the allen key to remove the set screw on the rotor. 90010 90008 90010 90008 90094 90010 90008 90010 90008 90099 90010 90008 90010 90008 The final step is to push the shaft out from the rotor using the similar pin punch tool technique implemented previously to remove the bearings.90010 90008 90010 90008 90108 90010 90008 90010 90008 90113 90010 90008 90010 90008 Now you can replace the shaft with the new one. Carefully tap the new shaft back to the rotor. 90003 90004 Make sure the flat surface on the shaft is position directly above the hole for the set screw. 90005 90006 90010 90008 Assemble back the rotor to the stator and followed by inserting back the collar and the circlip to the shaft’s rear end. You are done! 90010 90008 90010 90008 90010 90008 90004 D.L. ENGINEERING — The Sky is Home 90005 90010 90008 90004 www.dle-tech.info 90005 90010.90000 How does a brushless electric motor work? 90001 90002 The article How Electric Motors Work explains how 90003 brushed motors 90004 work. In a typical DC motor, there are permanent 90003 magnets 90004 on the outside and a spinning 90003 armature 90004 on the inside. The permanent magnets are stationary, so they are called the 90003 stator 90004. The armature rotates, so it is called the 90003 rotor 90004. 90013 90002 The armature contains an 90003 electromagnet 90004.When you run electricity into this electromagnet, it creates a magnetic field in the armature that attracts and repels the magnets in the stator. So the armature spins through 180 degrees. To keep it spinning, you have to change the poles of the electromagnet. The brushes handle this change in polarity. They make contact with two spinning electrodes attached to the armature and flip the magnetic polarity of the electromagnet as it spins. 90013 90002 This setup works and is simple and cheap to manufacture, but it has a lot of problems: 90013 90020 90021 The brushes eventually wear out.90022 90021 Because the brushes are making / breaking connections, you get sparking and electrical noi 90022 90021 The brushes limit the maximum speed of the motor. 90022 90021 Having the electromagnet in the center of the motor makes it harder to cool. 90022 90021 The use of brushes puts a limit on how many poles the armature can have. 90022 90031 90002 With the advent of cheap computers and power transistors, it became possible to «turn the motor inside out» and eliminate the brushes.In a 90003 brushless DC motor 90004 (BLDC), you put the permanent magnets on the rotor and you move the electromagnets to the stator. Then you use a computer (connected to high-power transistors) to charge up the electromagnets as the shaft turns. This system has all sorts of advantages: 90013 90020 90021 Because a computer controls the motor instead of mechanical brushes, it’s more precise. The computer can also factor the speed of the motor into the equation.This makes brushless motors more efficient. 90022 90021 There is no sparking and much less electrical noise. 90022 90021 There are no brushes to wear out. 90022 90021 With the electromagnets on the stator, they are very easy to cool. 90022 90021 You can have a lot of electromagnets on the stator for more precise control. 90022 90031 90002 The only disadvantage of a brushless motor is its higher initial cost, but you can often recover that cost through the greater efficiency over the life of the motor.90013 90002 For more information on brushless motors, check out the links that follow. 90013 90052 Related HowStuffWorks Articles 90053 90052 More Great Links 90053 .90000 The Electric Motor — Edison Tech Center 90001 The electric motor was first developed in the 1830s, 30 years after the first battery. Interestingly the motor was developed before the first dynamo or generator. 90002 90003 90004 90005 90006 90007 90008 Above: The first Davenport motor 90009 90010 90005 90012 1.) History and Inventors: 90013 90006 90015 1834 — 90016 90015 Thomas Davenport 90016 of Vermont developed the first real electric motor ( ‘real’ meaning powerful enough to do a task) although Joseph Henry and Michael Faraday created early motion devices using electromagnetic fields. The early «motors» created spinning disks or levers that rocked back and forth. These devices could not do any work for humankind but were important for leading the way to better motors in the future.Davenport’s various motors were able to run a model trolley on a circular track and other tasks. The trolley later turned out to be the first important application of electric power (it was not the light bulb). Rudimentary full sized electric trolleys were finally built 30 years after Davenport’s death in the 1850s. 90007 90006 90015 The electric motor’s world impact before light bulbs: 90016 90002 Trolleys and the connected power systems were very expensive to build but transported millions of people to work in the 1880s.Until the growth of the power grid in the 1890s most people (middle and low classes) even in cities did not have the electric light in the home. 90007 90006 It was not until тисячі вісімсот сімдесят три that the electric motor finally achieved commericial success. Since the 1830s thousands of pioneering engineers have improved motors and created many variations. See other pages for more detail on the electric motor’s vast history.90007 90010 90028 90029 90015 Motor leads to the generator: 90016 90002 After weak electric motors were developed by Faraday and Henry, another early pioneer named 90015 Hippolyte Pixii 90016 figured out that by running the motor backwards he could create pulses of electricity. By the 1860s powerful generators were being developed. The electrical industry could not begin until generators were developed because batteries were not an economical way to power society’s needs.Read about 90015 generators and dynamos here> 90016 90037 90004 90005 90012 2.) How Motors Work 90013 90006 Electric motors can be powered by alternating (AC) current or direct current (DC). DC motors were developed first and have certain advantages and disadvantages. Each type of motor works differently but they all use the power of the electromagnetic field.We will talk about the very basic principals of electromagnetic fields in motors before you can move on to the different types of motors. 90007 90006 AC electric motors use a secondary and primary winding (magnet), the primary is attached to AC grid power (or directly to a generator) and is energized. The secondary receives energy from the primary without directly touching it. This is done using the complex phenomena known as induction.90007 90006 90008 Right: an engineer works on custom modifications to an octocopter drone. Eight tiny DC motors create enough power to lift pounds of payload. Newer motor designs like this use rare earth metals in the stator to create stronger magnetic fields in smaller, lighter packages. 90009 90007 90010 90005 90010 90028 90029 90037 90004 90005 90010 90005 90010 90028 90004 90005 90008 Above: a universal motor typically found in most power tools.It has a heavy dense rotor. 90009 90010 90005 90008 Above: the induction motor may have a «squirrel cage» or hollow rotating coil or a heavy armature. 90009 90010 90028 90029 90012 2.a) Parts of an electric motor: 90013 90006 There are many kinds of electric motors but in general they have some similar parts. Each motor has a 90015 stator 90016, which may be a permanent magnet (as shown in the ‘universal motor’ above) or wound insulted wires (An electromagnet like in the photo above-right).The 90015 rotor 90016 sits the middle (most of the time), and is subject to the magnetic field created by the stator. The rotor rotates as its poles are attracted and repelled by the poles in the stator. Watch our video below showing how it works. This video covers a brushless DC motor where the rotor is on the outside, in other motors the same principle is in reverse, with the electromagnets on the outside. Video (1 minute): 90007 90081 90082 90006 90015 Strength of a motor: 90016 90002 The strength of the motor (torque) is determined by voltage and the length of the wire in an electromagnet in the stator, the longer the wire (which means more coils in the stator) the stronger the magnetic field.This means more power to turn the rotor. 90015 See our video which applies to both generators and motors to learn more. 90016 90007 90090 90015 Armature 90016 — the rotating part of the motor — this used to be called a rotor, it supports the rotating copper coils. In the photo below you do not see the coils because they are tightly tucked into the armature. A smooth housing protects the coils from damage.90007 90094 90015 90016 90007 90015 Stator 90016 — The housing and coils that make up the exterior of the motor. The stator creates a stationary magnetic field. 90094 90007 90094 90008 Above: four distinct coils are clearly seen in this stator (the armature was removed) 90009 90007 90006 90015 Winding or «Coil» 90016 — copper wires wound around a core to used to create or receive electromagnetic energy.90007 90006 Wire used in the windings MUST be insulated. In some photos you will see what looks like bare copper wire windings, it is not, it is simply a enameled with a clear coating. 90007 90094 90007 90006 90015 Copper 90016 is the most common material for windings. 90015 Aluminum 90016 is also used but must be thicker to carry the same electrical load safely.Copper windings allow for a smaller sized motor. More on Copper> 90007 90006 90015 Burning out a motor, troubleshooting: 90016 90002 If a motor is run for too long or at excessive load, it may «burn up». This means that that the high temperature caused the winding insulation to break down or melt, the windings then short when they touch and the motor is damaged. You can also burn up a motor by putting more voltage into it than the winding wires are rated for.In that case the wire will melt at the weakest point, severing the connection. You can test a motor to see if it has burned out this way by testing for Ohms (resistance) on a multi-meter. In general you want to look for black marks in the windings when you check a motor. 90007 90090 90002 90015 Squirrel Cage 90016 — the second coil in an induction motor, see below to see how it works 90002 90015 Induction 90016 — the generation of electromotive force in a closed circuit by a varying magnetic flux through the circuit.In AC power the power level is going up and down, this charges the winding for a moment creating a magnetic field. When the power drops in the cycle the magnetic field can not be sustained and it collapses. This action transfers power through magnetics into the other winding or coil. LEARN MORE about induction here. 90007 90012 3.) Types of AC Electric Motors 90013 90003 90004 90137 90138 90006 90015 Alternating Current (AC) Motors: 90016 90007 90143 90010 90028 90029 90006 90015 3.a) Induction Motor 90002 3.b) Universal Motor (can use DC or AC) 90002 3.c) Synchronous Motors 90002 3.d) Shaded-Pole Motors 90002 90016 90007 90006 90002 90015 See our page dedicated to the Induction Motor here> 90016 90007 90094 90007 90090 This is a powerful motor which can be used with both AC and DC power. 90007 90090 90015 Advantages 90016: 90002 -High starting torque, and small size (good for there common use in consumer power tools) 90002 -Can run at high speeds (great for washing machines and electric drills) 90007 90006 90015 Disadvantages: 90016 90002 -Brushes will wear out over time 90007 90090 90015 Uses: 90016 appliances, hand held power tools 90007 90094 90007 90094 90015 See the video below: 90016 90007 90094 90186 90082 90002 90007 90003 90004 90192 90138 90012 3.c) Synchronous Motors (Selsyn Motor) 90013 90143 90010 90028 90029.90000 90001 DC Motors — principles of operation 90002 90003 90004 90005 In any electric motor, operation is based on simple electromagnetism. A current-carrying conductor generates a magnetic field; when this is then placed in an external magnetic field, it will experience a force proportional to the current in the conductor, and to the strength of the external magnetic field.As you are well aware of from playing with magnets as a kid, opposite (North and South) polarities attract, while like polarities (North and North, South and South) repel. The internal configuration of a DC motor is designed to harness the magnetic interaction between a current-carrying conductor and an external magnetic field to generate rotational motion.90006 90004 Let’s start by looking at a simple 2-pole DC electric motor (here red represents a magnet or winding with a «North» polarization, while green represents a magnet or winding with a «South» polarization). 90006 90004 Every DC motor has six basic parts — axle, rotor (a.k.a., armature), stator, commutator, field magnet (s), and brushes. In most common DC motors (and all that BEAMers will see), the external magnetic field is produced by high-strength permanent magnets 90010 1 90011. The stator is the stationary part of the motor — this includes the motor casing, as well as two or more permanent magnet pole pieces.The rotor (together with the axle and attached commutator) rotate with respect to the stator. The rotor consists of windings (generally on a core), the windings being electrically connected to the commutator. The above diagram shows a common motor layout — with the rotor inside the stator (field) magnets. 90006 90013 90014 90003 90004 The geometry of the brushes, commutator contacts, and rotor windings are such that when power is applied, the polarities of the energized winding and the stator magnet (s) are misaligned, and the rotor will rotate until it is almost aligned with the stator’s field magnets.As the rotor reaches alignment, the brushes move to the next commutator contacts, and energize the next winding. Given our example two-pole motor, the rotation reverses the direction of current through the rotor winding, leading to a «Flip» of the rotor’s magnetic field, driving it to continue rotating.90006 90004 In real life, though, DC motors will always have more than two poles (three is a very common number). In particular, this avoids «dead spots» in the commutator. You can imagine how with our example two-pole motor, if the rotor is exactly at the middle of its rotation (Perfectly aligned with the field magnets), it will get «stuck» there.Meanwhile, with a two-pole motor, there is a moment where the commutator shorts out the power supply (i.e., both brushes touch both commutator contacts simultaneously). This would be bad for the power supply, waste energy, and damage motor components as well. Yet another disadvantage of such a simple motor is that it would exhibit a high amount of torque «Ripple» (the amount of torque it could produce is cyclic with the position of the rotor).90006 90020 90003 90020 90023 90024 90004 So since most small DC motors are of a three-pole design, let’s tinker with the workings of one via an interactive animation (JavaScript required): 90006 90027 90014 90003 90020 90031 90020 90023 90024 90004 You’ll notice a few things from this — namely, one pole is fully energized at a time (but two others are «partially» energized).As each brush transitions from one commutator contact to the next, one coil’s field will rapidly collapse, as the next coil’s field will rapidly charge up (this occurs within a few microsecond). We’ll see more about the effects of this later, but in the meantime you can see that this is a direct result of the coil windings ‘series wiring: 90006 90013 90014 90039 90004 90006 90020 90003 90020 90003 90004 There’s probably no better way to see how an average DC motor is put together, than by just opening one up.Unfortunately this is tedious work, as well as requiring the destruction of a perfectly good motor. 90006 90004 Luckily for you, I’ve gone ahead and done this in your stead. The guts of a disassembled Mabuchi FF-030-PN motor (the same model that Solarbotics sells) are available for you to see here (On 10 lines / cm graph paper).This is a basic 3-pole DC motor, with 2 brushes and three commutator contacts. 90006 90020 90023 90024 90004 The use of an iron core armature (as in the Mabuchi, above) is quite common, and has a number of advantages 90010 2 90011.First off, the iron core provides a strong, rigid support for the windings — a particularly important consideration for high-torque motors. The core also conducts heat away from the rotor windings, allowing the motor to be driven harder than might otherwise be the case. Iron core construction is also relatively inexpensive compared with other construction types.90006 90004 But iron core construction also has several disadvantages. The iron armature has a relatively high inertia which limits motor acceleration. This construction also results in high winding inductances which limit brush and commutator life. 90006 90004 In small motors, an alternative design is often used which features a ‘coreless’ armature winding.This design depends upon the coil wire itself for structural integrity. As a result, the armature is hollow, and the permanent magnet can be mounted 90060 inside 90061 the rotor coil. Coreless DC motors have much lower armature inductance than iron-core motors of comparable size, extending brush and commutator life. 90006 90005 Diagram courtesy of MicroMo 90004 The coreless design also allows manufacturers to build smaller motors; meanwhile, due to the lack of iron in their rotors, coreless motors are somewhat prone to overheating.As a result, this design is generally used just in small, low-power motors. BEAMers will most often see coreless DC motors in the form of pager motors. 90006 90013 90014 90039 90004 90006 90020 90003 90020 90003 90004 Again, disassembling a coreless motor can be instructive — in this case, my hapless victim was a cheap pager vibrator motor.The guts of this disassembled motor are available for you to see here (On 10 lines / cm graph paper). This is (Or more accurately, 90060 was 90061) a 3-pole coreless DC motor. 90006 90004 I disembowel ’em so you do not have to … 90006 90020 90023 90024 90004 To get the best from DC motors in BEAMbots, we’ll need to take a closer look at DC motor behaviors — both obvious and not.90006 90086 90005 90060 90089 Notes: 90090 90061 90004 1. Other (generally either very large, or fairly old) DC motors use windings to produce the external field as well. By using permanent magnets, modern DC motors are more efficient, have reduced internal heating, and use less power.90006 90004 2. The following 3 paragraphs borrow fairly liberally from material on a number of pages of the MicroMo web site. This is an excellent site, and goes into much greater detail on the ins and outs of coreless motor construction and performance. Particular attention should be given to their pages on Motor Construction, and on the Development of Electromotive Force .90005 90006 90020 90024.