BLDC MOTOR

Brushless DC Motors are designed with NdFeB magnets to have high power and torque density, and small size
structure. It is good for EV, Electric Vehicle and battery power applications. High efficiency, wide speed range,
low EMI and no brush maintenance are Brushless Motor benefits.
1. Energy efficiency motor adopts the high magnetic energy permanent magnet to have high power and torque
density, and small size structure.
2. Innovating structure to have high torque performance.
3. Electrical commutation can perform low noise, low EMI and no brush maintenance.
4. Lower rotor inertia and good heat dissipation, windings of Brushless DC motors are in the stator. In a
brush-type motor, the winding is in the rotor.
5. Power and torque density are much higher than the conventional motors.
6. Without mechanical commutation, motor speed can be over 10,000 rpm.
7. The innovating structure has an excellent feature in energy saving during heavy-load operation, and high
torque at low speed driving. The high efficiency range is much wider than conventional motors.

BLDC vS IM vs DC Brush Motor

Topic

Brushless DC Motors Induction Motor

DC Brush Motor

Compact Size, Light

Weight

Low Rotor Inertia,

High Speed Rotation

No Rotor Copper Lose

High Efficiency

Heat Dissipation
No Carbon & Electric
Flash
Low Speed Torque

No Brush maintenance

Over Load Capability

X
Excellent

Acceptable

X Poor

Working
A Brushless DC Motor is operated by means of an electronic six-step
commutation system. Unlike its Brush DC Motor counterparts, the Brushless
DC Motor does not contain any carbon brushes. Instead, the electromagnets
within the motor remain stationary along with the armature, while the encased
permanent magnets rotate, generating torque. The Brushless DC Motor is
synchronous; both the stator and the magnetic field generate the same
frequency, therefore avoiding any type of slip most induction motors exhibit.
What is Six-Step Commutation?
Six-step commutation is a cost-effective means of electronic commutation,
due to the simple and relatively inexpensive feedback and drive devices. In
six-step commutation, only two out of the three Brushless DC Motor windings
are used at a time. Steps are equivalent to 60 electrical degrees, so six steps
makes a full, 360 degree rotation. One full 360 degree loop is able to control
the current, due to the fact that there is only one current path. Six-step
commutation is typically useful in applications requiring high speed and
commutation frequencies. A six-step Brushless DC Motor usually has lower
torque efficiency than a sine-wave commutated motor.

What is voltage constant?

Rpm/Volts

What is current constant?

Torque/Current

3. What is the stator?

The stator contains coils of wire which will have voltage induced into them as
the magnets pass over them.
4. What is the difference between Wye and Delta windings?
Wye windings give high torque at low rpm, and Delta windings give low torque
at low rpm.
5. How do you find the voltage constant?
Take the No load speed and divide by the input voltage applied.
6. What happens when voltage is increased?
The speed of the motor increases as well.
7. What happens when the voltage is decreased?
The speed of the motor decreases also.
8. If you have two different input voltages and the same torque, what
happens to the current and why?
The current will stay the same because of the Torque Constant. Torque is
only relative to current, not voltage.
9. How many phases are in a brushless motor?
Three
10. What is the difference between a DC brushed motor and DC

brushless motor?
A DC Brushed Motor needs only physical contact to pass current through its
motor windings to allow commutations. A DC Brushless Motor needs a driver
to commutate.
Bonus Questions
How many pulses per revolution in a 4 pole and 8 pole motor for one hall
sensor?
4 Pole Motor has 2 pulses per revolution: 4/2 = 2 Pulses
8 Pole Motor has 4 pulses per revolution: 8/2 = 4 Pulses
12. How do you change the direction of the motor?
Switch around the Phases along with the Hall Sensors.
Brushless Motor FAQs
Q: Can different voltages be applied other than the specified voltage?
A: Yes, you can apply different voltages, although, you must keep in mind that
there is a speed limit for the bearings. If you increase the voltage, the speed
will increase. If you decrease the voltage then the speed will decrease. For
example, if a Brushless DC Motor is rated to run at 3000 RPM no load with
36VDC, the motor will run 2000 RPM with 24VDC. The maximum speed,
torque, and power are directly proportional to the voltage.
Q: How can I achieve a higher power output without purchasing a new
motor?
A: This can be approached in two ways: increasing the voltage being applied
or increasing the current being supplied to the motor. The equation:
Power = (Oz in x )
Power = Watts (W)
1351.2
= Speed (RPM)
Q: Do Hall Sensors need to be used to drive a Brushless DC Motor?
A: No, Hall sensors are only needed for feedback systems requiring a Hall
Effect Sensor. A Brushless Motor may be sensorless where the back EMF is
used to run the motor.
Q: What is Stall Torque?
A: Stall Torque is the amount of torque where the shaft ceases to move.
Q: What is Rated Torque?
A: Rated Torque is where the motor can operate continuously at a safe level.

Q: What is Peak Torque?

A: Peak Torque is where the motor can operate for a brief period of time, but
will be damaged if run for longer periods.
Q: Can I run a Brushless DC Motor off of a battery?
A: Yes, along with a Brushless DC Controller.
Q: Can I run a Brushless DC Motor off of 110 VAC?
A: Yes, along with a Brushless DC Controller.
Q: Will a Brushless DC Motor slow down when the load is increased?
A: In closed-loop control, the Brushless DC Motor will not slow down, as long
at the torque of the motor is strong enough. However, it will always slow down
with open-loop control.

Q: Is it possible to burn up a Brushless DC Motor by giving it too much

load?
A: Yes. It is protected if the controller has a current limit provision.

BLDC MOTOR CONTROLLER

An electronic Brushless DC Controller (also known as a Driver, or Electronic
Speed Controller), replaces the mechanical commutation system utilized by a
Brush DC Motor, and is required by most Brushless DC Motors to operate. In
a Brushless DC Motor controller, either a Hall Effect Sensor or Back EMF
(Electromotive Force) is used to identify the position of the rotor.
Understanding the orientation of the rotor is crucial to operating the Brushless
DC Motor.

The Hall Effect uses three hall sensors within the Brushless DC Motor to help
detect the position of the rotor. This method is primarily used in speed
detection, positioning, current sensing, and proximity switching. The magnetic
field changes in response to the transducer that varies its output voltage.
Feedback is created by directly returning a voltage, because the sensor

operates as an analogue transducer. The distance between the Hall plate and
a known magnetic field can be determined with a group of sensors, and the
relative position of the magnet can be deduced. A Hall sensor can act as an
on/off switch in a digital mode when combined with circuitry.
Back EMF, also known as the Counter-Electromotive Force, is caused by a
changing electromagnetic field. In a Brushless DC Motor, back EMF is a
voltage that occurs where there is motion between the external magnetic field
and the armature of the motor. In other words, the voltage is developed in an
inductor by an alternating or pulsating current. The polarity of the voltage is
constantly the reverse of the input voltage. This method is commonly used to
measure the position and speed of the Brushless DC Motor indirectly, and due
to the lack of Hall Sensors within the controller, these are often referred to as
sensorless controllers.