Brushed to brushless??

[93 FORD BRONCO]

I've had this idea for a while but never acted on it due to the fact that i don't know much about electric motors. Is it possible to turn a regular brushed motor into a brushless motor?

[Charlie-III]

Not really, it's way faster/cheaper/easier to just buy a BL motor.

[Trubble]

Originally Posted by 93 FORD BRONCO

I've had this idea for a while but never acted on it due to the fact that i don't know much about electric motors. Is it possible to turn a regular brushed motor into a brushless motor?

We're just talkin' smack here, money and physics aren't holding us back, how would you go about doing that?

Would you be trying to accomplish something usable, or just strictly a 'proof of concept' type of a project?

[benoj]

If it were possible it wouldn't be like a typical brushless motor since a bushed motor has the magnets fixed and the windings spin on the armature while a bl motor the windings are fixed and the magnet is in the center which spins


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[Duuuuuuuude]

You could totally do it. All you'd need is to strip the brushed motor down, throw the brushes, endbell, and springs away, pry the magnets out of the can, throw them away too. Then, press the armature and stacks off of the shaft. Throw those away too.

Now that you've got that done, clean the can and bearings up really really good. Lube the bearing too. It'd suck to go through all this work and not have lubed bearings.

Grab a chunk of steel and machine out a new armature to fit into the can. Figure out how many winds you want, and how you want to wind it. Going sensored? Solder all of the components onto a custom cut circuit board...hall sensors, temp sensor, all that good stuff.

Next, find a nice neo magnet that will fit on the old shaft and inside of the armature that you've wound. Press it into place.

Machine a new endbell, put the armature in the can, followed by the rotor and the sensor ring. Wire it all up and test for smoke. Go play!

Easy peasy.

[Trubble]

Far more complicated than the plan I had, but it does provide a usable (inrunner) style of motor.

My plan was simply to machine a mount, bolt it to the table,
ditch the endcap, brushes, etc off the brushed motor,
slip the comm end of the armature in the mount on the table and crank 'er down tight,
connect the three wires from the brushless ESC to the three segments on the comm. (pretty much requires you to use a 3 pole brushed motor, the most popular in use at this time),
the can just sits in it's normal place.

Sounds to me like a brushed motor just got converted to a brushless outrunner.
I don't have enough education or experience to know if it's just that easy, but if it works, proof of concept is done.

To make it at all usable one could machine an adapter that bolts to the PTO end of the can, and put some holes in it for mounting a prop or pulley.

If the original intent was to make an inrunner that could be bolted back into where the brushed motor came out of,
instead of bolting the mount to the table, bolt it to a square plate (or make the mount itself square),
make a similar square plate for the PTO end,
4 rods will connect the two,
the PTO end adapter previously mentioned can then get a small length of 1/8th" or 5mm shaft (instead of bolting on a prop),
the square plate on the PTO end will have a hole in the middle for the output shaft to come through, and two more roughly 25mm apart which is where you'd bolt it to your stock motor plate.

I think before I went this route, even a notorious skin-flint like me would just cut loose with a handful of 20's and buy something that actually stood a chance of working.