instructables

Solenoid Motor With Long Throw

by jbike

This solenoid motor has an extra long throw to make
it a more interesting display, and uses electronic
switching instead of a cam and mechanical switch for
longer life. The flywheel, connecting rod, and solenoid
stand are 3D printed. The flywheel has a 625ZZ
bearing to make for quieter, smoother operation. The
motor runs from 5 volts to 12 volts; switching is done
with a surface mount AO3400 N MOSFET with gate
driven via P and N type bipolar transistors mounted
on a postage stamp sized bit of perfboard. For
detecting the right time to power the solenoid, a
latching type hall effect sensor was used; a north
magnet in the flywheel turns it on, while a south
magnet turns the output off.

https://youtu.be/D_u9hbVnvf8

Solenoid Motor With Long Throw: Page 1

Step 1: Materials Used

Base: 1/2" birch plywood, 3" x 8" Plastic used in 3D printer: 1.75mm PLA- black

Screws: #4 pan head sheet metal screws for securing 0- 80 screw x 1/2" and nut for connecting rod to
parts to wood base solenoid plunger

1 ea. 625ZZ bearing, ebay M5 x .8 x 25mm screw for securing flywheel

Electronic parts: AO3400 N MOSFET, SMT from ebay (100 for $2.50)

Hall Effect sensor US1881LUA-AAA-000-BU from 1 large red straw from Wendy's for solenoid bobbin
Mouser.com
1 large black straw from McDonalds for solenoid
2 ea. 1/8" x 1/8" cylinder magnets bobbin

2N2222 NPN transistor piece of paper cardstock for solenoid end pieces

2N3906 PNP transistor #28 awg wire, approx. 300 feet

2 ea. 1K SMT resistor 1/4" steel rod x 3" for solenoid core, hardware store

1 ea. 3.3 K 1/4 w resistor

1 ea. BYV 26E diode

Download (https://cdn.instructables.com/ORIG/FIG/6TTT/J6B0M2DE/FIG6TTTJ6B0M2DE.f3d)
http://www.instructables.com/ORIG/FIG/6TTT/J6B0M2DE/FIG6TTTJ6B0M2DE.f3d
…

(https://cdn.instructables.com/ORIG/FIG/6TTT/J6B0M2DE/FIG6TTTJ6B0M2DE.f3d)
Download (https://cdn.instructables.com/ORIG/FVW/7V03/J6B0M2DG/FVW7V03J6B0M2DG.f3d)
http://www.instructables.com/ORIG/FVW/7V03/J6B0M2DG/FVW7V03J6B0M2DG.f3d
…

(https://cdn.instructables.com/ORIG/FVW/7V03/J6B0M2DG/FVW7V03J6B0M2DG.f3d)
Download (https://cdn.instructables.com/ORIG/F2I/QIUD/J6B0M2DO/F2IQIUDJ6B0M2DO.f3d)
http://www.instructables.com/ORIG/F2I/QIUD/J6B0M2DO/F2IQIUDJ6B0M2DO.f3d
…

(https://cdn.instructables.com/ORIG/F2I/QIUD/J6B0M2DO/F2IQIUDJ6B0M2DO.f3d)
Download (https://cdn.instructables.com/ORIG/FTU/3P65/J6B0M2DP/FTU3P65J6B0M2DP.f3d)
http://www.instructables.com/ORIG/FTU/3P65/J6B0M2DP/FTU3P65J6B0M2DP.f3d
…

(https://cdn.instructables.com/ORIG/FTU/3P65/J6B0M2DP/FTU3P65J6B0M2DP.f3d)

Solenoid Motor With Long Throw: Page 2

Step 2: Construction
Cut the 1/4" steel rod to 3" long. Visit Wendy's and
McDonald's to get straws that allow the rod to slide
easily inside the straws. There is a slight diameter
difference in the straws; one can fit inside the other,
so they become stronger. A bit of super glue can be
placed on the inner straw to hold it in place inside the
other straw. Cut 2 ea 1/4" x 1" washers out of
cardstock and glue them onto the straws to form a
bobbin for the wire 1.5" long. Leave about 1/2" of the
straw beyond the end of one washer, so that the
straw (with steel rod inside) can be placed in the
chuck of a cordless drill. Then wind approximately
300 feet of #28 awg wire onto the bobbin with the
drill, leaving 6" of excess wire at the beginning and
end of the coil.
Print the 3D solenoid bracket and mount to one end
of the base. Drill a hole for the 0-80 screw in one end
turns smoothly. Place a small washer on the end of
the flywheel crank and use a screw to retain the
connecting rod to the flywheel crank.
Make the electronic switch on a piece of perfboard. I
used just the side with the holes since I wanted the
board to lay flat against the base. Position the NPN
facing down, and the PNP transistor facing up so that
the emitters of the transistors can directly connect.
Construct with reference to the photos and the circuit
diagram. Place the magnets in the flywheel cutouts at
Solenoid Motor With Long Throw: Page 3
of the rod and file the rod end a bit so the rod can fit
in the connecting rod small end and connect to the
rod.
Remove the metal shields from the 625ZZ bearing
with a fine flat blade screwdriver; pry the shields out.
Dip the bearing in paint thinner to remove the bearing
grease, dry, then lubricate with a light machine oil. 3D
print the flywheel and press the bearing into the
flywheel with a socket slightly smaller than the
bearing outside diameter. Do not press on the inner
bearing race. A vise will make pressing the bearing
into the flywheel with the socket easier.
3D print the flywheel stand and mount to the base
with screws after test fitting the connecting rod and
solenoid positions. Assemble the flywheel onto the
stand with the M5 x .8 screw. Test that the flywheel
the back of the flywheel as shown in the pictures.
One magnet should be magnetic north, the other
magnetic south; thus the latching Hall sensor will turn
on when triggered with one magnetic polarity and turn
off with the other magnetic polarity. Test the operation
of the motor by holding the sensor near the magnets,
while giving the flywheel a spin. The motor should
operate best at one position; hot glue the sensor in
that position to the stand.
Solenoid Motor With Long Throw: Page 4
Solenoid Motor With Long Throw: Page 5
Step 3: Operation

The motor operates well from 6 volts to 12 volts, though lower voltages are better because the operation of the
long throw crank can be better observed. Do not operate above 12 volts since the MOSFET gate isn't rated for
more than 12 volts. A counterweight can be placed inside one of the flywheel cut outs to smooth the vibrations at
higher speeds.

Solenoid Motor With Long Throw: Page 6