Electric motor

24 Articles

An exploded view of an electrostatic motor from manufacturer C-Motive. There is a silvery cylinder on the left, two half silver and half golden disks on either side and two thinner gold disks in the center. A square mountin plate is on the right hand side next to one of the silver/gold disks.

Electrostatic Motors Are Making A Comeback

October 29, 2024 by 21 Comments

Electrostatic motors are now common in MEMS applications, but researchers at the University of Wisconsin and spinoff C-Motive Technologies have brought macroscale electrostatic motors back. [via MSN/WSJ]

While the first real application of an electric motor was Ben Franklin’s electrostatically-driven turkey rotisserie, electromagnetic type motors largely supplanted the technology due to the types of materials available to engineers of the time. Newer dielectric fluids and power electronics now allow electrostatic motors to be better at some applications than their electromagnetic peers.

The main advantage of electrostatic motors is their reduced critical materials use. In particular, electrostatic motors don’t require copper windings or any rare earth magnets which are getting more expensive as demand grows for electrically-powered machines. C-Motive is initially targeting direct drive industrial applications, and the “voltage driven nature of an electrostatic machine” means they require less cooling than an electromagnetic motor. They also don’t use much if any power when stalled.

Would you like a refresher on how to make static electricity or a deeper dive on how these motors work?

Why Electric Trains Sound The Way They Do

October 5, 2024 by 20 Comments

If you’re a seasoned international rail traveler you will no doubt have become used to the various sounds of electric locomotives and multiple units as they start up. If you know anything about electronics you’ll probably have made the connection between the sounds and their associated motor control schemes, but unless you’re a railway engineer the chances are you’ll still be in the dark about just what’s going on. To throw light on the matter, [Z&F Railways] have a video explaining the various control schemes and the technologies behind them.

It’s made in Scotland, so the featured trains are largely British or in particular Scottish ones, but since the same systems can be found internationally it’s the sounds which matter rather than the trains themselves. Particularly interesting is the explanation of PWM versus pattern mode, the latter being a series of symmetrical pulses at different frequencies to create the same effect as PWM, but without relying on a single switching frequency as PWM does. This allows the controller to more efficiently match its drive to the AC frequency demanded by the motor at a particular speed, and is responsible for the “gear change” sound of many electric trains. We’re particularly taken by the sound of some German and Austrian locomotives (made by our corporate overlords Siemens, by coincidence) that step through the patterns in a musical scale.

Not for the first time we’re left wondering why electric vehicle manufacturers have considered fake internal combustion noises to make their cars sound sporty, when the sound of true electrical power is right there. The video is below the break.

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Making EV Motors, And Breaking Up With Rare Earth Elements

July 9, 2024 by 83 Comments

Rare earth elements are used to produce magnets with very high strength that also strongly resist demagnetization, their performance is key to modern motors such as those in electric vehicles (EVs). The stronger the magnets, the lighter and more efficient a motor can be. So what exactly does it take to break up with rare earths?

Rare earth elements (REEs) are actually abundant in the Earth’s crust, technically speaking. The problem is they are found in very low concentrations, and inconveniently mixed with other elements when found. Huge amounts of ore are required to extract useful quantities, which requires substantial industrial processing. The processes involved are ecologically harmful and result in large amounts of toxic waste.

Moving away from rare earth magnets in EV motors would bring a lot of benefits, but poses challenges. There are two basic approaches: optimize a motor for non-rare-earth magnets (such as iron nitrides), or do away with permanent magnets entirely in favor of electromagnets (pictured above). There are significant engineering challenges to both approaches, and it’s difficult to say which will be best in the end. But research and prototypes are making it increasingly clear that effective REE-free motors are perfectly feasible. Breaking up with REEs and their toxic heritage would be much easier when their main benefit — technological performance — gets taken off the table as a unique advantage.

A white male in a green shirt sitting next to a tall rectangular robot made of green and black components with an aluminum frame. In front of him are a variety of components from several windshield wiper motor assemblies. Casings, gearboxes, and the like are strewn across the wooden table.

A Wiper Motor 101

February 2, 2024 by 22 Comments

Need a powerful electric motor on the cheap? [Daniel Simu] and his friend [Werner] show us the ins and outs of using windshield wiper motors.

Through many examples and disassembled components, the duo walk us through some of the potential uses of wiper motors to power a project. Some of the nuggets we get are the linear relationship of torque to current (10-15A max) and speed to voltage (12-15V DC) on these units, and some of the ways the wiring in these motors is a little different than a simple two wire DC motor.

They also discuss some of their favorite ways to control the motors ranging from a light switch to an Arduino. They even mention how to turn one into a big servo thanks to a project on Hackaday.io and a few modifications of their own. [Simu] also discusses some of the drawbacks of wiper motors, the most evident being that these motors use nylon gears which are prone to stripping or failing in other ways when subjected to high torque conditions for too long.

If you recognize [Simu], it may be from his robotic acrobat built with wiper motors. Want to see some more wiper motor hacks? How about a 3D scanner or making sure your wipers always keep the beat?

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A brass-and-wood replica of Faraday's motor

Replicating Faraday’s 200-Year-Old Electric Motor

September 18, 2023 by 13 Comments

Although new electric motor types are still being invented, the basic principle of an electric motor has changed little in the past century-and-a-half: a stator and a rotor built of magnetic materials plus a bunch of strategically-placed loops of wire. But getting even those basic ingredients right took a lot of experimentation by some of the greatest names in physics. Michael Faraday was one of them, and in the process became the first person to turn electricity into motion. [Markus Bindhammer] has recreated Faraday’s experiment in proper 19th century style.

Back in 1821, the very nature of electricity and its relation to magnetism were active areas of research. Tasked with writing an article about the new science of eletromagnetics, Faraday decided to test out the interaction between a current-carrying wire and a permanent magnet, in a setup very similar to [Markus]’s design. A brass wire is hanging freely from a horizontal rod and makes contact with a conductive liquid, inside of which a magnet is standing vertically. As an electric current is passed through the wire, it begins to rotate around the magnet, as if to stir the liquid.

[Markus]’s video, embedded after the break, shows the entire construction process. Starting from rods and sheet metal, [Markus] uses mostly hand tools to create all basic parts that implement the motor, including a neat knife switch. Where Faraday used mercury as the conductive liquid, [Markus] uses salt water – cheaper and less toxic, although it does eventually eat up the brass wire through electrolysis.

While not particularly useful in itself, Faraday’s motor proved for the first time that electric energy could be converted into motion through magnetism, leading to a whole class of ultra-simple motors called homopolar motors. It would be a while before experiments by the likes of Tesla and Ferraris led to modern AC motors. If you don’t like your motors magnetic, you can use electrostatics instead.

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Go-Kart Reverse Without The Pain

June 26, 2022 by 20 Comments

Go-karts are a huge amount of fun, but often lack the most basic of mechanical conveniences such as a reverse gear. You can’t start a small four-stroke engine in reverse, so their simple chain drive transmissions lack the extra cogs to make it happen. Enter [HowToLou], who has given his go-kart a reversing option by the addition of an electric motor.

It’s an extremely simple arrangement, the motor is a geared 12 V item which drives a V-belt to the axle. The motor is mounted on a pivot with a lever, such that normally the belt isn’t engaged, thus reverse can be selected by pulling the lever. A simple button switch applies power to the motor, meaning that the machine can travel sedately backwards on electric power.

We’re not entirely convinced by the integrity of some of his fixings and it would be interesting to see how much the V-belt wears under the influence of the pulley when not engaged, but as an alternative to a full gearbox we can see the point. But then again as regular readers may know, we’re more used to full electric traction.

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Heavy-Duty Starter Motor Powers An Awesome Drift Trike

December 15, 2021 by 11 Comments

Starter motors aren’t typically a great choice for motorized projects, as they’re designed to give engines a big strong kick for a few seconds. Driving them continuously can often quickly overheat them and burn them out. However, [Austin Blake] demonstrates that by choosing parts carefully, you can indeed have some fun with a starter motor-powered ride.

[Austin] decided to equip his drift trike with a 42MT-equivalent starter motor typically used in heavy construction machinery. The motor was first stripped of its solenoid mechanism, which is used to disengage the starter from an engine after it has started. The housing was then machined down to make the motor smaller, and a mount designed to hold the starter on the drift trike’s frame.

A 36V battery pack was whipped up using some cells [Austin] had lying around, and fitted with a BMS for safe charging. The 12V starter can draw up to 1650 amps when cranking an engine, though the battery pack can only safely deliver 120 amps continuously. A Kelly controller for brushed DC motors was used, set up with a current limit to protect the battery from excessive current draw.

The hefty motor weighs around 50 pounds, and is by no way the lightest or most efficient drive solution out there. However, [Austin] reports that it has held up just fine in 20 minutes of near-continuous testing, despite being overvolted well beyond its design specification. The fact it’s operating at a tenth of its rated current may also have something to do with its longevity. It also bears noting that many YouTube EVs die shortly after they’re posted. Your mileage may vary.

For a more modern solution, you might consider converting an alternator into a brushless electric motor. Video after the break.

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