Construction

of a DC
Motor.
Written by Aaron Chu

1
Table of Contents
Abstract: How does a DC Motor work?.....................................................................................3
Designing and planning the motor.............................................................................................4
Aim.............................................................................................................................................6
Hypothesis..................................................................................................................................6
Questioning and predicting........................................................................................................6
First build...................................................................................................................................6
Apparatus (first build)............................................................................................................6
Method (first build)................................................................................................................7
Final product (first build).......................................................................................................8
Evaluation of first build.........................................................................................................9
Second build...............................................................................................................................9
Apparatus (second build).......................................................................................................9
Method (second build).........................................................................................................10
Risk assessment for both builds...............................................................................................11
Final product (second build)................................................................................................13
Evaluation of second build...................................................................................................14
Appendix 1: Parts of a DC Electric Motor...............................................................................16
A pair of permanent magnets in a simple motor..................................................................16
Pairs of electromagnetic coils in a more complex motor.....................................................16
Armature..............................................................................................................................17
Rotor coil(s).........................................................................................................................17
Split-ring commutator..........................................................................................................17
Brushes.................................................................................................................................18
Axle......................................................................................................................................18
Appendix 2: Advantages and Disadvantages of AC and DC Electricity..................................19
DC Power.............................................................................................................................19
AC Power.............................................................................................................................19
How does the type of current affect the motors?.....................................................................20
References................................................................................................................................22
Evaluation of sources...............................................................................................................24

2
Abstract: How does a DC Motor work?
In order for a DC motor to convert electrical energy into mechanical energy, it must produce
a force to create torque.
The rotor produces a force due to the motor effect since,
⃗
F =⃗
B Ilsinθ
But because,

τ =r ⃗
F
Then when we combine the 2 formulae, we derive the equation for torque experienced in a
motor at a given angle,

τ =n ⃗
B IA sin θ
Where A is the cross-sectional area of the armature.
And n is the number of turns.
From this equation, when we want torque to be increased, we will need to either increase the
flux density, current, cross-sectional area, or number of turns.
However, as the rotational speed (ω ) increases, there will be an increase in induced emf
which according to Lenz’s law, acts in the direction to oppose the change. This will cause
back emf which slows down the acceleration of the motor until operating speed.

3
Designing and planning the motor
Idea Advantage Disadvantag Image Source
s es (number
in
reference
s)
Bottling Aesthetical Prone to 1
up the ly pleasing. overheating
motor Less messy since home
into a cables. made motors
canister. are
inefficient.

Making Can be cut Can cut 1

armature into an yourself
out of cut easy shape whilst doing
out to allow for it.
deodoran 3 different Unsanitary.
t cans. coils.

Using Easy to When the 1

blue tac use. motor
to mould produces
things heat, it can
together soften the
blue tac.

Pencil as Easy to Increases 2

an axle find. friction.

Conducti Conductive Hard to find. 2

ve metal and are
squares sturdy.

4
 Making a Easy to Might break 3
base and find and when
supports meets brief dropped.
out of of being an
lego. inexpensiv
e
household
item.
Easy to
work with.
More Improves Needs more 4
than 1 torque and wire and can
coil. reduces the be heavier.
reliance on
the split
ring
commutato
r.

Therefore, I will be basing my design out through the evaluation of these ideas.

5
Aim
To build a simple working DC motor.

Hypothesis
The larger the area, stronger the magnetic field, larger the current, larger the cross-sectional
area, and the more turns, then the torque will increase because of the motor effect.

Questioning and predicting

These are some questions I considered when assembling the motor.
- Can I make a motor that’s brushless?
- How could I use electromagnets instead of permanent ones?
- To what extent does the strength of the magnets affect the torque?
- How efficient can I make a motor using materials found at home?
- What is the minimum amount of money I can spend to build a decent motor?
- Where can I find these materials?
- What happens if the wires didn’t have rubber or an enamel coating?
- Would the rotor be powerful enough to be used as a fan?
- How much does back emf affect the motor?

First build
Apparatus (first build)
Rubber coated wire 1mm 4m
Conductive metal squares 2x
Lego 119 pieces
Electrical tape 2m
Strong ceramic magnets 4x
Cardboard 0.5m
Super glue
Battery pack
Rod 10mm 20cm length
Knife
Scissors

6
Method (first build)
1. Build a foundational structure out of lego pieces including a slot for magnets, brushes,
and axle.
2. Cut up a piece of cardboard into a strip 4x20 cm and roll it around the rod 4x to make
the base of the armature.
3. Cut up 2 other pieces from the same cardboard into rectangles 6x8 cm and use super
glue to glue one on the bottom and the other on the top of the armature for the wire
coils to wrap inside.
4. Measure 12 cm from the base of the rod and roll up 10 rounds of electrical tape to
increase the diameter of the rod in that area.
5. Cut off 2 cm of the rubber from the wire and place the base of the cut tip onto the
electrical tape and then start wrapping the armature.
6. Wrap both the upper and lower sides of the armature first with 6 winds each.
7. Then use the cut side of the wire to reference cutting the other side form the rest of the
wire.
8. Then use the electrical tape to tape the tips of the wire together to hold them into
place this will be ½ of the split ring commutator.
9. Then get the rest of the wire and repeat steps 5 to 8 but instead, wrapping on top of
the cardboard and making sure the tips of the wire are 90deg apart before tapping it
up.
10. Place the finished armature and split ring commutator into the lego supports.
11. Using the conductive metal squares, tape a strand of wire to the silhouette to improve
conductivity. Do this with both of the metal squares.
12. Then cut the rubber off the wire and place it so it just touches the split ring
commutator. This will act as our brushes to transfer current through the coils.
13. Wire up the base of the squares with extra wire that connects to a power supply.
14. Finally, place the magnets on the sides of the structure as shown in the picture to
produce a B.

7
Final product (first build)

8
Evaluation of first build
Overall, this was a very inefficient build. Being built out of lego, it wasn’t sturdy and
provided too much friction and not enough stability to hold in the conductive metal squares to
hold the commutator. Although it did work, there needs to be changes to the overall design
and materials to make it more efficient.

Second build
Apparatus (second build)
Rubber coated wire 1mm 4m
Conductive metal squares 2x
Plywood 5 pieces
Electrical tape 2m
Strong ceramic magnets 4x
Cardboard 0.5m
Steel nails 15mm
Super glue
Battery pack
Rod 10mm 20cm length
Knife
Scissors
Drill

9
Method (second build)
1. Build a foundational structure out of the blocks of wood including a slot for magnets,
brushes, and a drilled part for the axle. It should look like the picture below.
2. Nail in the metal squares on the beside where the split ring commutator is going to go
for the brushes.
3. Cut up a piece of cardboard into a strip 4x20 cm and roll it around the rod 4x to make
the base of the armature.
4. Cut up 2 other pieces from the same cardboard into rectangles 6x8 cm and use super
glue to glue one on the bottom and the other on the top of the armature for the wire
coils to wrap inside.
5. Measure 12 cm from the base of the rod and roll up 10 rounds of electrical tape to
increase the diameter of the rod in that area.
6. Cut off 2 cm of the rubber from the wire and place the base of the cut tip onto the
electrical tape and then start wrapping the armature.
7. Wrap both the upper and lower sides of the armature first with 6 winds each.
8. Then use the cut side of the wire to reference cutting the other side form the rest of the
wire.
9. Then use the electrical tape to tape the tips of the wire together to hold them into
place this will be ½ of the split ring commutator.
10. Then get the rest of the wire and repeat steps 5 to 8 but instead, wrapping on top of
the cardboard and making sure the tips of the wire are 90deg apart before tapping it
up.
11. Place the finished armature and split ring commutator into the drilled slots to hold the
axle.
12. Using the conductive metal squares, tape a sheet of aluminium to the silhouette to
improve conductivity. Do this with both of the metal squares.
13. Then cut the rubber off the wire and place it so it just touches the split ring
commutator. This will act as our brushes to transfer current through the coils.
14. Wire up the base of the squares with extra wire that connects to a power supply.
15. Finally, place the magnets on the sides of the structure as shown in the diagram to
produce a B.

10
Risk assessment for both builds.

11
12
Final product (second build)

13
Evaluation of second build
Summary
Since the base and supports were made out of wood, it is much sturdier which makes it more
reliable and efficient.
Axle
The axle was reused from the first build as it worked efficiently. It was made of wood to be
lighter and cheaper, however it does cause more friction, lowering the efficiency of the
overall motor.
Armature
The armature was made of cardboard which was glued to the axle to hold the coils. This was
also reused from the first build as it worked efficiently. It allows the coils to be wound up
horisontally and vertically to increase the number of coils.
Coils
The coils were reused from the first build as it was working efficiently. They are wound up
both horisontally and vertically as the armature can only hold so much in one direction.
Further, this winding allows the force to be applied every 90 degrees, where a single pair of
commutators will be weakest. Therefore, increasing the efficiency of the motor.
Commutator
The commutator was reused from the first build as it was working efficiently. During the trial
run however, there was sparks that built up which caused the tip of the wire to oxidise so I
needed to sand it to improve conductivity.
In this design, there are two pairs of commutators in order to supply current to the two
different positions of winds as one is 90 degrees from the other. This allows the force to be
applied where the other is weakest, therefore improving efficiency.
Brushes
The brushes have been changed since the first design in order to improve the contact between
the brushed and the commutator. Instead, the metal brackets were nailed into the base to
provide more structural integrity for the brushes to rest on.
The brushes itself were changed from open wires to a small aluminium sheet. This improves
the conductivity as there is now more surface area that is touching the commutator whilst the
brackets secure it from moving out of place.

14
Base
The base has been changed from the first build. Instead of a base made of lego, I’ve decided
to craft it out of wood by gluing pieces together to form the base for this motor. I’ve included
two blocks with drills inside for the axel to spin on and an extra pair of blocks for the
magnets to rest. This increases the overall stability of the motor as now I can also drill in the
metal brackets to assist the brushes and to stop them from moving out of place when in
operation.
Magnets
The magnets were kept the same from the first build since they were strong enough.
Conclusion
After all the changes made from the first build, this motor now has an increase in efficiency
and reliability, majority due to the wooden base, providing structural integrity to the motor.

15
Appendix 1: Parts of a DC Electric Motor
For the external magnets, one of the following arrangements is used:

A pair of permanent magnets in a simple motor.

Description
The magnets on the side of a simple motor usually are radial magnets, used to produce a
radial magnetic field to increase the flux density (⃗
B).
Function
The magnets provide the motor with a sufficient ⃗
B for in order to make the motor work, using
the motor effect.

Pairs of electromagnetic coils in a more complex motor.

Description
Similar to fixed magnets, the electromagnetic coils provide sufficient ⃗
B in order for the rotor
to spin. However, this is with the use of solenoids.
Function
It’s common for a motor to have electromagnets instead as they tend to have a stronger B
which increases the torque. This is because,

B=μ o∋ ¿ ¿
⃗
L
⃗
B∝ N
Where N is the number of turns.
As its easier to increase N then to increase the strength of the magnet.

Further, for solenoids, their ⃗

B is controlled through electricity, making them able to turn on
and off which permanent magnets cannot achieve.
Furthermore, it allows the motor to change speed so you don’t need to change the current,
instead, change the electromagnetic coils which makes it more easier to control.

16
Other parts in a DC motor include:

Armature
Description
The armature is a moving part that is wrapped by the coils and sits on an axle.
Function
It facilitates the interaction between the current (I) in the coils and the ⃗
B.
This part can be made more efficient by making it out of lighter material as then the force
will be used to accelerate the rotor more efficiently.

Rotor coil(s)
Description
These are wires, usually made of conductive material such as copper or aluminium. They
wrap around the armature to be interacted with ⃗
B.
Function
As the current (I) flows around the coil, the perpendicular section creates a force due to the
motor effect. The force creates torque which is proportional to the number of turns around the
armature as seen,

τ =n ⃗
B IA sin θ
This means motors usually have lots of coils around the armature in order to increase the
amount of torque.
This part can be made more efficient by either making it out of higher conductive materials to
improve flux linkage or to have multiple turns to increase torque.

Split-ring commutator
Description
This has a semi-crescent shape and is made out of conductive material. It is connected to both
sides of the coil and rotates with the armature to prevent tangling of the wires.
Function
As the motor works due to the motor effect, every 180°, the current must be reversed in order
for the motor to keep its momentum in the same direction or it will rock back and forth.
The split ring commutator facilitates the change in current every 180° in order to keep
reversing the force, so that it points in the opposite direction to keep the motor moving in the
same direction. It achieves this by connecting the coil to the power supply.

17
This part can be made more efficient by keeping the sides lubricated in order to reduce
friction, which is slowing the rotor down.

Brushes
Description
The brushes are a non-moving part in the motor that needs regular maintenance through the
friction caused by ‘brushing’ the split-ring commutator. They are connected to the power
supply.
Function
These are made out of conductive lubricants like graphite in order to provide current from the
power supply to the coils.
This part can be made more efficient by also keeping the sides lubricated and regular
maintenance in order to reduce friction.

Axle
Description
The axle is located in the centre of the armature to provide a pivot point in which the
armature rotates by. It is usually lubricated in order to reduce friction.
Function
This is what transfers the rotational energy into an appliance or for use.
This part can be made more efficient by also lubricating the axle to reduce friction.

18
Appendix 2: Advantages and Disadvantages of AC and
DC Electricity.
DC Power
A direct current (DC) is a flow of an electric charge in one direction.
Advantages
- No progress or lag in the circuit
- Reactive power was not produced.
- able to hold electricity.
- fewer insulation and conductors are needed.
- Lower resistance
- Can be used to demonstrate circuits due to their simplicity.
Disadvantages
- difficult stoppage of the current
- Hard to convert DC to AC.
- potent electrolytic result
- Due to commutation issues, high voltage electricity cannot be produced.

AC Power
An alternating current (DC) is a flow of an electric charge that oscillates directions
periodically.
Advantages
- reduced power loss at high voltages
- Simple to transform.
- simpler and less expensive to switch to DC.
- Simple to turn off while the electricity is on
- Negative and positive terminals aren’t a concern.
- Maintenance, repair, and generation are less expensive.
- Their reliability and efficiency make it common in industrial cases.
Disadvantages
- higher voltage than the intended value is needed.
- impacted by capacitors and coils.
- Unsuitable for transmission over extremely long distances
- At high voltages, more hazardous
- More intricate design
- constant loss of power in the DC transmission line

19
How does the type of current affect the motors?
As explained in page (n), a DC motor works under the principle of The Motor Effect.
However, an AC motor works differently as it works under Lenz’s and Faraday’s Laws.
There are 2 main components in an AC motor:
- Rotor: rotates.
- Stator: stationary.
Rotor
The rotor is made of conductive material in the shape of a cylinder, resembling a squirrel
cage with slits on the sides.

This is the part that rotates to produce rotational mechanical energy from electrical.
Stator
Comprises of 3 pairs of electromagnets out of phase by 120° connected to the AC supply.

The rotating ⃗
B produces a ∆ ⃗
B in which Faraday’s Law states that this produces an induced
EMF as seen through the equation,
dΦ
ε =−n
dt

Image
But since Lenz’s Law states that the current produced by the induced EMF will act to oppose
the change, therefore producing torque within the rotor as it spins to restore the initial ∆ ⃗
B.

20
AC motor
Advantages Why/how? Disadvantages Why/how?
More efficient Compared to a More complex and Systems and theory
DC motor. Since expensive. are more intricate
it produces more and make it harder to
torque with the produce.
same amount of
energy.
Less maintenance This is due to Higher voltage. Can be dangerous if
required. less moving not used properly.
parts.
Less moving parts. Lowers the The speed of the rotor Instead of the split
amount of is controlled by the ring commutator, it
friction, current frequency. works on the
therefore frequency of an AC
increasing (w). current changing
instantaneously.
Longer life span. This is due to
less
maintenance.
Less power Due to less
consumption. friction acting in
the system.

DC motor
Advantages Why/how? Disadvantages Why/how?
Simple and Systems and Less efficient. Compared to an AC
inexpensive. theory are less motor. Since it
intricate, making produces less torque
it easier to with the same
produce and amount of energy.
learn.
Lower voltage. Can be safer and More maintenance This is due to more
incur less required. moving parts.
electricity bills.
More moving parts. Increases the amount
of friction, therefore
decreasing (w).
Shorter lifespan. This is due to more
maintenance.
Higher power Due to more friction
consumption. acting in the system.
The speed of the Instead of an AC, a
armature is controlled DC motor uses a split
by the current. ring commutator to
change the direction
of current every
180deg.

21
References
Source 1
Khambhala, N. (2017). How to make an electric motor at home. YouTube. [ONLINE].
Available: https://www.youtube.com/watch?v=0p2QTE26VOA&t=144s
Retrieved: 09/03/2024.
Source 2
Dixon, T. (2023). HSC physics: how to build a DC motor video and step by step guide.
Matrix education. [ONLINE].
Available: https://www.matrix.edu.au/hsc-physics-how-to-build-a-dc-motor-video-and-step-
by-step-guide/
Retrieved: 09/03/2024.
Source 3
Robinson, J. (2020). How to make a DC motor out of lego: how a motor operates. YouTube.
[ONLINE].
Available: https://youtu.be/BfG5mE17xF8?si=kc0SmJmWQl4nKYWq
Retrieved: 09/03/2024.
Source 4
Ribeiro, WC. (2017). DIY Electric Motor with e-waste #2. YouTube. [ONLINE].
Available: https://youtu.be/0qYWmaf_3JA
Retrieved: 09/03/2024.
Source 5
Blake, A. (2022). 9 Ways to Build Your Own Electric Motor. Make use of. [ONLINE].
Available: https://www.makeuseof.com/how-to-build-electric-motor/.
Retrieved: 09/03/2024.
Source 6
The Complete Guide to DC Motors. RS. (2024). [ONLINE].
Available: https://au.rs-online.com/web/content/discovery/ideas-and-advice/dc-motors-
guide#
Retrieved: 09/03/2024.
Source 7
How a DC motor actually works. Magnetic innovations. (2024). [ONLINE].
Available: https://www.magneticinnovations.com/faq/dc-motor-how-it-works/

22
Retrieved: 09/03/2024.

23
Evaluation of sources
Source 1
Currency

- 2017
Relevance

- Relates to how to make a motor at home.

Authority

- Author(s): Khambhala, N.
- Institution: video from YouTube.
Accuracy

- Has been revisited, revised, reviewed.

- Supported by evidence.
- References listed.
- Primary source.
Purpose

- To inform on how to make an electric motor at home.

Therefore, this source is reliable and valid.

Source 2
Currency

- 2023
Relevance

- Relates to how to build a DC motor video and step by step guide.

Authority

- Author(s): Dixon, T.
- Institution: matrix education.
Accuracy

- Has been revisited, revised, reviewed.

- Supported by evidence.
- References listed.
- Primary source.
Purpose

- To inform on to how to build a DC motor video and step by step guide.

Therefore, this source is reliable and valid.

24
Source 3
Currency

- 2020
Relevance

- Relates to How to make a DC motor out of lego: how a motor operates.

Authority

- Author(s): Robinson, J.
- Institution: video on YouTube.
Accuracy

- Has been revisited, revised, reviewed.

- Supported by evidence.
- References listed.
- Primary source.
Purpose

- To inform on How to make a DC motor out of lego: how a motor operates.

Therefore, this source is valid and reliable.

Source 4
Currency

- 2017
Relevance

- Relates to DIY Electric Motor with e-waste.

Authority

- Author(s): Ribeiro, WC.

- Institution:
Accuracy

- Has been revisited, revised, reviewed.

- Supported by evidence.
- References listed.
Primary source.
Purpose

- Informs on DIY Electric Motor with e-waste.

Therefore, this source is valid and reliable.

25
Source 5
Currency

- 2022
Relevance

- Relates to 9 Ways to Build Your Own Electric Motor.

Authority

- Author(s): Blake, A.
- Institution: Make use of.
Accuracy

- Has been revisited, revised, reviewed.

- Supported by evidence.
- References listed.
- Secondary source.
Purpose

- Informs on 9 Ways to Build Your Own Electric Motor.

Therefore, this source is valid and reliable.

Source 6
Currency

- 2024
Relevance

- Relates to The Complete Guide to DC Motors.

Authority

- Author(s): none listed.

- Institution: RS
Accuracy

- Has been revisited, revised, reviewed.

- Supported by evidence.
- References listed.
- Secondary source.
Purpose

- Informs on The Complete Guide to DC Motors.

Therefore, this source is valid but not reliable.

26
Source 7
Currency

- 2024
Relevance

- Relates to How a DC motor actually works.

Authority

- Author(s): none listed.

- Institution: Magnetic innovations.
Accuracy

- Has been revisited, revised, reviewed.

- Supported by evidence.
- References listed.
- Secondary source.
Purpose

- Informs on How a DC motor actually works.

Therefore, this source is valid but not reliable.

27