Custom-built electric motor car with 3D printed components

Electric Motor Car Project

Physics Application
Engineering Design

Project Overview

For this Physics 12 class project, I collaborated with a classmate to build a brushed DC motor. We then expanded on the initial goal by incorporating our motor into a small car, pushing our understanding of electrical and mechanical systems integration.

Key Components

  • Custom-built brushed DC motor with hand-wound copper coils
  • 3D printed chassis and structural components
  • AA battery pack for power supply
  • Simple switch mechanism for control
  • Optimized wheels for minimal resistance

Design and Construction Process

Our approach to building the electric motor car involved several key steps:

  1. Researching DC motor principles and design considerations
  2. Prototyping the motor components and testing for efficiency
  3. Designing and 3D printing the car chassis and wheels
  4. Integrating the motor with the chassis and power supply
  5. Troubleshooting and optimizing the final design for performance

Technical Challenges

Throughout the project, we encountered and overcame several challenges:

  • Ensuring proper electrical connections and insulation
  • Minimizing friction in the drivetrain
  • Managing weight distribution for efficinet power delivery

Skills Developed

This project was instrumental in developing several key technical skills:

  • Soldering and electrical wiring techniques
  • 3D modeling and printing for custom parts
  • Understanding of electromagnetic principles in motors
  • System integration and troubleshooting
  • Collaborative problem-solving in an engineering context

Learning Outcomes

This project provided valuable hands-on experience in designing and building components that work together as part of a unified system. It deepened our understanding of electromagnetism, mechanical design, and the practical applications of physics principles.

Future Improvements

While our electric motor car was successful, we identified several areas for potential future improvements:

  • Implementing a more sophisticated control system for variable speed
  • Exploring different rotor designs, such as rotors with mutliple coils
  • Designing a stiffer chassis for improved power delivery

This project not only reinforced our understanding of physics principles but also ignited a passion for electromechanical systems and sustainable transportation solutions. It serves as a foundation for future explorations in electric vehicle technology and robotics.