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3D Printed Electric Motors As a Step Towards Self-Replicating Machines

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3D Printed Electric Motors As a Step Towards Self-Replicating Machines i-SAIRAS2020-Papers (2020) 5020.pdf 3D PRINTED ELECTRIC MOTORS AS A STEP TOWARDS SELF-REPLICATING MACHINES Virtual Conference 19–23 October 2020 Abdurrazag Elaskri1, Alex Ellery2 1Carleton University, 1125 Colonel By Drive, Canada, E-mail: [email protected] 2Carleton University, 1125 Colonel By Drive, Canada, E-mail: [email protected] ABSTRACT an electrical conductor is one of the essential ele- ments in an electric motor. However, the lack of ma- This research addresses the application of 3D printing ture AM technologies able to produce a high electri- technologies in innovative electrical machinery. To cal conductivity material such as copper is considered date, there is a lack of fabricated devices with elec- as a challenge. A conventional DC motor is also con- tromechanical functionality for parts entirely manu- structed of permanent magnets (PMs), and the most factured using only Additive Manufacturing (AM) powerful PM's should have an organized granular technologies. This study provides a new and different structure that is a challenge to rebuild with a 3D approach to create a fully 3D printed electric motors, printing machine. Furthermore, 3D printing the rotor with a focus on an additively manufactured iron core, and stator cores with high permeability soft magnetic winding, insulation, and permanent magnet. We in- materials that determine the motor performance are vestigate how to develop 3D printed motor with mul- still under development. Based on the above princi- ti-material and multi-technique without using embed- ples, the brushed DC electric motor (BDCM) is se- ding devices. Several prototypes of radial and axial lected to be entirely 3D printed. This selection is re- flux DC electric motors were fabricated and tested. sulting in the use of fewer components where the Their functionality indicated the potential of achiev- electrical power source in a classical BDC motor is ing 3D-printed motor using inexpensive, commercial- connected to the rotor winding through a commutator ly available equipment. A good plan application is to and brushes without the need for electronic commuta- use the 3D printed motor as the core component of a tion based on hall position sensors. Besides, all other self-replicating machine. Suppose such a machine motor types are derived from its design. The selection was deployed on the Moon. It could be a robotic sys- of the AM technique in this research revolved around tem that uses lunar materials to replicate itself and, considering several issues, including the availability, eventually, fabricate a broad range of future space materials, costs, process of manufacturing, and the assets. state of the art of the AM technologies available. For 1 INTRODUCTION comparative purposes, the rotor core is produced considering different types of additively manufac- Fabrication of functional objects utilizing AM is a tured material using Fused Deposition Modelling new research area, and the basic approach is to em- (FDM) and Cold Spray Additive Manufacturing bed off-the-shelf devices on or in a printed object by (CSAM). Several prototypes of Self-excited DC mo- inserting conductive wires into the printed geometry tor were 3D printed in order to eliminate the use of during the printing process. In recent studies, conduc- PMs in the stator using different materials and differ- tive inks were also used to form electronic circuits ent printing techniques, followed by the building pro- into 3D printed parts [1]. As an example, in [2], the cess of pancake motor in order to eliminate the use of writers describe the process in which the 3D printed the copper coils. Optimization techniques are not part was embedded with electrical components and addressed in this research since the first goal is to 3D electronic circuits made of conductive ink. Regard- print electric motor, not improve its performance. less of the employment of AM technologies for pro- Also, the building of the pancake motor was only to ducing a wide range of dielectric and metallic materi- develop the coils technique to eliminate the copper als, previous studies about fabricating electromechan- coil winding. ical devices are relatively limited. All attempts to 3D- print electric motors only considered the main struc- 3 RELEVANT PREVIOUS ATTEMPTS TO ture of the rotor and stator. The main challenge of 3D PRINT INTERACTIVE OBJECTS building electric motors with current manufacturing Fabrication of functional objects is a new research systems is the limited available materials that can be area, and the standard approach is to embed off-the- processed using 3D printing machines. For instance, shelf devices inside the printed object. H. Peng et al. i-SAIRAS2020-Papers (2020) 5020.pdf [3] developed a custom print head with two-wire ball-bearings. Fabrication of operative objects using feeders that can deliver the wire within five-degrees AM is a new research area. The fundamental way is of freedom 5DOF on an FDM printer. They used this to embed off-the-shelf devices on or in a printed ob- for winding copper wire coil to induce a magnetic ject, including conductive wires, into the printed ge- field and winding soft iron over a plastic structure to ometry throughout the printing method. In recent form highly magnetic permeability poles. They researches, conductive inks were such as silver ink, demonstrated this by fabricating a 6-pole motor step- also used to form electronic circuits into 3D printed per stator (i.e. a reluctance motor rotor). Savage et al. parts. Although the employment of AM technologies [4] showed how 3D-printing could build interactive for constructing a wide range of dielectric and metal- objects by embedding a machine vision-based system lic materials, previous studies about fabricating elec- for sensing human input in physical controls, such as tromechanical devices are comparatively limited. All joysticks, buttons and sliders. Hook et al. [5] embed- efforts to 3D-print electric motors only considered ded small three-axis wireless accelerometers in the the main structure of the rotor and stator. The little moving parts of a 3D-printed object to tracking experimentation on the capabilities of AM on the movement. Furthermore, RevoMaker [6] presented development of products with mixed materials and the idea of inserting premade circuits inside a folded different technologies, such as circuit boards and cuboid, then printing over its facets representing electric motors, shows a gap in the literature. This computer muse. Savage et al. [7] also developed study presents a new approach to creating a fully 3D placing scanning marks and stickers on a solid model printed electric motors, including all motor parts such surface composed of sculpting materials, allowing as the rotor core with the field winding, the stator them to be converted into 3D-printed geometry. They core with stator winding or permanent magnets, insu- then mounted electronics and sensors inside the 3D- lation and the outer frame. We examine how to de- printed item. Other researchers have created interac- velop electric motor with multi-material and multi- tive objects by adding off-the-shelf sensors and ac- technique to attain a 3D printed motor that can build tuator parts during the printing process, including without embedding devices. 3D-printed light pipes [8], interactive speakers [9], 3 FABRICATING AND TESTING OF RADI- pneumatic device controls [10], hydraulically actuat- AL-FLUX DC MOTOR ed robotic structures [11] and capacitive touch sen- sors for interactive objects [12]. Voxel8 [13] devel- An electric motor is consisting of a stator and a rotor, oped an FDM printer that can print with both ther- separated by an air gap. The stator is stationary and moplastic and conductive silver paste. In addition to holds the PMs, while the rotor is the rotating section embedding off-the-shelf electronic components such and carries the windings. The rotor is usually pro- as motors, this made printing a complete quadcopter duced of silicon steel, presented in thin lamination possible, including the circuits. Researchers have sheets, and cut by laser to shape the desired patterns. recently investigated different techniques to insert These sheets are attached to form the final shape of conductive wires into 3D-printed geometry, thus pro- the rotor cores [19]. In this study, the brushed DC ducing 3D-printed interactive objects. Kim et al. [14] motor was chosen to be studied and 3D-printed. This demonstrated early results of embedding a copper selection was based on the simplicity of this type of wire on an airflow duct built by FDM to demonstrate motors, where the electric power source in a classical multi-material 3D-printed electronics. Bayless et al. BDC motor is connected to the rotor winding through [15] studied embedding wire by adding a wire- a commutator and brushes, and therefore no need for printing tool head to the RepRap 3D-printer to manu- electronic commutation based on hall position sen- facture hybrid wire/plastic parts. Bas [16] tested sors [19]. Different methodologies were used in this printing over a copper wire using a rotary ring to ori- study to achieve a fully 3D-printed motor are dis- ent the laid wire and extruding filament to cover it, as cussed in the following sections. We have evolved an example of single-layer wiring prints. Skylar-Scott furthest in 3D printing electric motors and have et al. [17] introduced a combination of direct ink printed and tested all components except for the cop- writing with a focused
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