Theoretical approach: The working principle of a BLDC motor is if a conductor containing current is positioned in a magnetic field, it experiences a force. Due to the effect of reactive force, the magnet will face an equal and reverse force. Once the permanent magnet is activated, the current-carrying conductor remains fixed.
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Once the Stator coil is operated by a supply source, it turns out to be an electromagnet and begins generating a steady region in the air gap. The rotor keeps rotating because of the force created between electromagnet stator and permanent magnet rotor.
Due to the switching of windings as high and low signals, similar winding is energized as north and south poles. The fixed magnet rotor with north and south poles makes alignment with stator poles which generates motor rotation. Thus, the motor drives in a clockwise direction.
Mathematical approach: The value of the torque can be calculated from the following equation:
Where k is a constant value,
ΦS is the flux of a stator,
ΦR is the flux of a stator,
θ is the angle of the torque.
The phases of the stator follow the clockwise direction of the machine as in the following figure:
Brushless DC motors are constructed with three main parts, such as a stator, rotor, and hall sensor. Based on the windings of Stator, BLDC can be categorized as a single-phase, two-phase or three-phase motor.
Stator: Stator of a BLDC motors is composed of stacked steel laminations containing windings. These windings can be organized in star or delta arrangement. Most BLDC motors have a three-phase star connection with the Stator. All winding is assembled with multiple interconnected coils and coils are positioned in every slot. The stator needs to be selected with the accurate level of the voltage according to the capability of the power supply.
Rotor: A permanent magnet is located in a rotor in BLDC. There are two to eight pole-pairs in a rotor. The flux density of a material needs to be high to gain the maximum torque in the motor. An accurate magnetic material for the rotor is required to generate appropriate magnetic field density.
Hall Sensor: The windings of the stator need to be stimulated for the rotation of the motor. A hall sensor is operated based on the principle of hall-effect. It is generally used to find the location of the rotor and convert it into an electrical signal. The hall-effect sensor implanted in the stator senses the location of the rotor. Usually, three hall sensors are implanted into most BLDC motors. Each sensor produces low and high signals to display its location in the BLDC motor.
The efficiency of the motor and propeller are two main important matters in BLDC. Power and efficiency are related to Torque, RPM, current, and voltage.
Mechanical power for a KV Brushless DC motor is shown in the following graph:
Electrical power for a KV Brushless DC motor is shown in the following figure:
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The motor efficiency of a KV Brushless DC motor is shown in the following figure:
The relationships among heat losses, torque current, RPM, maximum power, total power, and maximum efficiency are shown in the following figures:
In the left graph, the horizontal lines represent heat losses. In the middle graph, the maximum power curve has been shown. In the right graph, the maximum efficiency curve has been shown.
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BLDC motors have more benefits than brushed DC motors and induction motors. BLDC motors have higher speed, high dynamic response, high powerful reaction, high capacity, long lifespan, noiseless operation, etc. BLDC motors are very useful when space and weight are crucial matters. This motor is very advantageous for huge applications in the automotive, aerospace, consumer, and medical industries.
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A DC pump motor is a staple across manufacturing, construction, mining, and many more industries. They have lots of ranges, applications, and sizes, from teeny-tiny motors in medical equipment to ones generating thousands of horsepower.
Brushed and brushless are the two most common types of DC motors. The physics of how they work are similar, but their design and performance output are very different. Brushed motors are widespread, but brushless motors are becoming more popular. Although they both convert electronic energy into mechanical energy, they still have many differences between them. Here are 5 Advantages of Brushless Motors:
Brushless DC pumps can generate more torque per watt than their brushed pump counterparts. They also have a high torque-to-weight ratio. This is one of the most appreciated advantages of brushless vs. brushed DC pump motors. Specific models of brushless pumps can generate even higher amounts of torque when they slow down.
Brushless motors have a better design that makes them more dependable. Conduction cools the motors; they don’t need airflow inside the motor to cool off. This means internal parts are entirely closed in, staying protected from dirt and other irritants.
There’s less electromagnetic interference, and brushless pumps can handle some environments better because they emit less sparks.
Because of their lack of brushes, brushless pumps don’t have any commutator erosion. The lifespan of brushed motors depends on the life of their brushes, which can be hard to predict. Brushless motors, on the other hand, last as long as their bearings. They’re more predictable and typically last for tens of thousands of hours. However, there may be some applications where the high lifespan of a brushless motor isn’t important.
Brushless motors have a more compact and straightforward design than their predecessors. Due to the lack of brushes, they make fewer vibrations, which makes them quieter. Healthcare industries value this because patient comfort is essential. The brushless motors also don’t have any ionizing sparks from the commutator.
Another advantage of brushless pump motors is that they can operate at higher speeds compared to brushed motors. This is helpful when supporting grinders, cutters, and blowers. Brushless motors can come in multi-pole varieties; this limits their speed but dramatically increases their torque.
There are many advantages of brushless vs. brushed DC pump motors. However, it’s likely every single one won’t be relevant to your situation. Find what works for you.
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