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Motor Options

A project log for Realistic Roller Coaster

An accessible interactive scale-model roller coaster

nolan-hergertNolan Hergert 12/26/2023 at 07:385 Comments

The requirements for this project are fairly unique. It needs to be a very small motor with precise motion at low speeds while still maintaining decent torque in not that high of cost or weight. More specifically:

Sounds impossible, right?! Turns out there are a number of options still, let's go through them!

Continuous servo-style motor

I've seen cheap brushed DC motors with gearboxes and encoders that are small and cheap. Here is an FS90 from Adafruit (https://www.adafruit.com/product/2442):Continuous Rotation Micro ServoA similar style was pursued by the Anki Drive team for their sort of similar toy car project (more like slot car racing), with brushed motors, a bevel gear and magnetic sensors. Here's a picture from the excellent teardown by Lee Teschler: https://www.microcontrollertips.com/teardown-inside-anki-overdrive-racecar-set/

Some positives include low cost and less power draw. The brushes on the motors should be able to last long enough for a toy too.

However, there are some downsides!


Stepper Motors

By outsourcing the "switching" brush mechanism to a microcontroller, brushless motors increase the resolution of the steps they are able to make at the turning level, no gearbox or feedback needed!

These types of motors are all over the place, but importantly still made cheaply ($1) in small electronic devices like DVD drives and cameras with zoom lenses. 

I had the opportunity on a vacation trip to Shenzhen to visit a few factories, and was able to go to a motor factory that made stepper motors among other things. They bothered to film me looking at things and asking questions, did a tea ceremony, and took me out to eat afterwards and made a video! It was flattering for just a guy with an idea, but maybe that was the point too!

Aaanyways, among lots of other learnings I took away some key points:

Brushless DC Motors

While intuitively they look the same as stepper motors, they have conflicting design constraints around speed and torque, documented well here: https://electronics.stackexchange.com/questions/79498/difference-between-brushless-motor-and-stepper-motor

Practically I haven't found small off-the-shelf brushless motors that are also cheap, small, and made in quantity, so I haven't pursued this option that much.

Discussions

Nolan Hergert wrote 12/29/2023 at 21:13 point

Thanks! Looking forward to trying out the options. I updated the post with some more information, but trying out a stepper motor is pretty enticing at the moment. I have to prove out the other parts of the project first though. We'll see!

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zoxoxu wrote 12/28/2023 at 21:57 point

Probably good to look at what others doe

https://hackaday.com/tag/tiny-robots/

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zoxoxu wrote 12/27/2023 at 16:54 point

Did you look at dynamical range? Xc330 for example.

Or k-power (cheaper )

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Nolan Hergert wrote 12/27/2023 at 18:41 point

Hi zoxoxu, thanks for asking! It looks like those servos start at around $10 and are pretty bulky, relative to my option of a double-sided 10mm stepper which is under $5 and is about 10mmx20mm. I'm pursuing a stepper for now, but might switch back in the future if it turns out to not be effective.

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zoxoxu wrote 12/28/2023 at 21:51 point

One thing that I love about the dynamixel range is their control board, daisy chain, quality protocol, precision and robust PID.

If you ever go back to DC motor, normal tiny RC servo for exemple, you can take the control board from the dynamixel and replace the one from the RC servo, it's a little Frankenstein but will give you the accuracy and will reduce a lot the noise because the pid doesn't oscillate when it reach position due to a better quality sensor without so much electrical noise.

Also saw someone making a tiny robot arm with RC servo and custom control board recently on here.

Don't underestimate the importance of the control system, size, resolution,...

And try to characterise what you need, torque/speed, even if it's an estimation. You will quickly rule out a lote of option.

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