Portescap R&D Intern
Demo Tools
I designed these based on orthopedic drills that use Portescap motors. They each showcase a motor and motor controller in the clear housing, left featuring a bevel geared output and right a direct drive motor. The motor controller (seen in right) works using hall effect sensors and magnets in the triggers, powered by 9 volt batteries. Pressing either trigger spins the motor at variable speed in either direction, and pressing both activates a tapping motion. I designed the housings in SolidWorks and 3D printed them, finishing with a clear coat. These demo tools are taken to trade shows to demonstrate how the motors are used in customer applications.
Rotor - Stator Mating Fixture
One problem identified in the assembly process was the strong magnetic attraction between the rotor magnets and the stator winding which could lead to damage in the bearings as the parts quickly accelerated and collided.
I worked with the lead test engineer to develop this assembly fixture to smoothly guide the stator housing onto the rotor with springs to cushion the magnetic force. I tested a variety of springs with different spring constants and different types of sliding bushings to optimize ease of use. The pedal actuated air collet securely holds the rotor while allowing users to quickly and easily remove and insert new parts.