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I am going to build a very simple brushed DC motor. The rotor will not be enclosed in a stator (the rotor will be built on a bench with free space around it), and I will using permanent magnets to make the external magnetic field.

I plan to compare the torque generated on the rotor with a non-iron core, with the torque generated on the rotor with an iron core (the two cores will have the same dimensions). I will do this at stall torque, and I think this will help me find the permeability of the iron core (assuming the non-iron core has a known permeability). The permeability isn’t constant in a ferromagnetic material such as a material made up of iron but knowing the permeability at stall torque should be enough for this assignment.

The best way to compare the two different torque values would probably be to just build a single rotor with a single coil and have the ability to just interchange the cores since this hopefully will eliminate some error when comparing the torque. This would mean that the coil can't be permanently attached to the first core, although the coil also has to be attached strong enough so that it doesn't fall off when the rotor spins. I got this suggestion from an electrical engineer, but I can't get in touch with him anymore. I could also build two different motors and try to make them as similar as possible to eliminate error, but the first option I think is better if it's possible to accomplish.

The dimensions of the cores will be 30x28x90mm (it's a rectangular shape, I couldn't find a cylinder), and I have the ability to cut and drill the iron core that I’ve bought, although I can only cut and drill across the short end. I plan to put the axis of rotation across the short end, but I don’t know if I should make the axis by drilling a hole (and inserting a small steel rod), or by cutting the core into two pieces and attaching each piece to a bigger prebuilt axis. This decision could influence my main issue, namely how I can switch the cores.

Any help is greatly appreciated, and please let me know if the question is unclear or badly formulated, and I will explain more about my assignment.

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  • $\begingroup$ You might be better off building more than one anyway. Differences caused by disassembly and reassembly can be comparable to differences in parts. It all depends on how you control the processes but it is also always good to have spare parts. $\endgroup$
    – Abel
    May 4 at 12:49

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