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iron less rotor DC motors
Brush DC Motor Basics
Construction of Portescap motors with
All DC motors, including the ironless rotor motors, are composed of three principle sub assemblies:
1. Stator
2. Brush Holder Endcap
3. Rotor
Stator Tube
Self Supporting High Packing
Density Rotor Coil
Sleeve or Ball
Bearing
Collector
High Efficiency High Strength
Rare Earth Magnet
Cable
Clamp
Metallic Alloy Brush
Commutation System
1. The stator
The stator consists of the central, cylindrical permanent magnet, the core which supports the bearings, and the steel tube
which completes the magnetic circuit. All three of these parts are held together by the motor front plate, or the mounting
plate. The magnetic core is magnetized diametrically after it has been mounted in the magnetic system
2. The Brush Holder Endcap
The Brush Holder Endcap is made of a plastic material. Depending on the intended use of the motor, the brush could be
of two different types:
  ? Carbon type, using copper grahite or silver graphite, such as those found in conventional motors with iron rotors.
  ? Multiwire type, using precious metals.
3. The Rotor
Of the three sub-assemblies, the one that is most characteristic of this type of motor is the ironless, bell-shaped rotor.
There are primarily four different methods of fabricating these ironless armatures utilized in present-day technology.
A — In the conventional way, the various sections of the armature are wound separately, then shaped and assembled
to form a cylindrical shell which is glass yarn reinforced, epoxy resin coated, and cured. It is of interest to note the
relatively large coil heads which do not participate in the creation of any torque.
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