This is the BORGI build intrusctions thread. BORGI is still in early develpment, but its already functional and a fun project to build! Building motors is very fascinating. You form some metal, copper wire, plastic, then hook it up to a controller and some batteries and it begins to live! Awsome! People normally don’t build motors from scratch, you normally buy them, so this is kinda unconventional. But BORGI is 100% DIY buildable design.
The build starts with gathering some materials.
You will need:
28x Nd N45 30x10mm Magnets
–> You can order them from: https://www.supermagnete.de/
we used the round magnets because they are very easy to to find. The motor would gain some more power and efficiency if we would use wedge shaped magnets. They would fill up almost the whole rotor space. So there is room form improvement on the magnet side. But lets start with round magnets for this version of the motor.
21 electromagnets: 7mm thick, 210* 4,6m 0.1mm enamel copperwire
–> we ordered from: https://www.rsonline-privat.de/Products/ProductDetail/Kupferlackdraht-0-1mm-Kupferdraht-Spule-PUR-isoliert-0-03-A-1144m-3377088
its quite expensive from RS but you can also get them on bigger spools from ALIBABA, you need quite a bit of the wire.
3x Hall Sensor Honeywell SS411A bipolar halleffect switch(latching) sensor.
–> get them from mouser, RS or any other electronics supplier, easy to find.
About 1000x1000x13 mm aluminum for the milling of the rotor parts as well as for the baseplate.
800x20mm round aluminum bar for the lathe
500g Hightemp 3D Printing material. We used a PLA-Lignin copolymer wich is stable up to 120 degC. Find something which is printable with your 3D Printer and withstands at least 80 degC. The coils can get quite hot, the more heat resistant your stator is, the more energy you can feed through the coils.
EPOXY or PUR resin, heatresitant at least up to 80 degC, more is better. We used a a PUR Bio Resin, which is non toxic and is stable up to 120 degC. It needs a bit more curing time but until now it seems to work alright for the purpose.
nuts and bolts --> list comming soon
As you wait for your material to arrive you can already make yourself familiar with the parts you will have to mill from aluminium and the parts you have to 3D print.
CNC milled parts:
- 1x basplate:
- 1x front rotor
- 1x back rotor
Turned parts on the lathe: ! include drawings for lathed parts !
- 7x big spacers which connect the baseplate with the stator
- 8x small spacers which connect the backrotor to the front rotor
3D printed parts:
- 21x coil templates
- 1x or more coil winding jigs
- 1x baseplate cover
- 1x stator base
- 1x stator top
- 1x stator cablehousing top
also you will have to make some copper busbars ! add drawings !
… DOCUMENTATION WORK IN PROGRESS!