The application of motors has spread to all kinds of fields. In order
to adopt different applications, various types of motors such as DC motors, induction motors, synchronous motors, switched reluctance motors from mill watts to several megawatts emerge. The synchronous motor has the advantages of high torque, precision and accuracy but it has poor speed regulation which limits its application. An induction motor has the advantages of simple structure and low price but results in low power factor. A switched reluctance motor without winding or permanent magnet in the rotor has a simple structure and low price. It has high torque over a wide range of speed, but noise and torque ripple limit its applications. DC motors are widely used in electric traction, rolling mill, hoisting equipment and in automation and control. In conventional DC motors, the mechanical commutation is implemented using brushes which result in mechanical friction, noise, electric spark and radio interference. These drawbacks can be overcome by brushless DC motors (BLDC). Since permanent magnets are placed in the rotor, they are also known as permanent magnet brushless DC (PMBLDC) motors. The BLDC motor is developed on the basis of brushed DC motors. In NEMA standard MG7-1987, a BLDC motor is defined as a type of self- synchronous rotary motor controlled by electronic commutation, where the rotor is a permanent magnet with rotor position sensor, and the related commutation circuit could be either independent or integrated to the motor. In 1955, Harrison and Rye developed a thyristor-based commutation circuit for a BLDC motor. CONSTRUCTION AND PRINCIPLE OF BLDC MOTOR BLDC motor is an inverted DC motor where the armature winding is placed on the stator, and the permanent magnet is on the rotor. In order to control the speed and direction of rotation, a rotor position sensor, a control circuit and power controller are included in the BLDC motor system. Figure 1 shows the block diagram of BLDC motor system
Figure 1: Block diagram of BLDC drive
The stator structure of the BLDC motor is similar to that of the synchronous or induction motor. Single or multi-phase symmetrical windings are embedded in the stator. Generally, star-connected windings are preferred in which three phase windings are symmetrically connected without a neutral point. The common winding types used in BLDC motors are concentrated full pitch windings, distributed full pitch windings and distributed short pitch windings. In the concentrated full pitch winding, the wires of same the phase are placed in the same slot which leads to better trapezoidal back EMF. In the distributed winding, the coils are dispersed evenly over the surface of the stator which leads to better cooling of the winding. In short pitched winding, the windings are shortened at the end of the winding which helps to save the copper material and weaken the torque harmonics. The rotor of the BLDC motor is constituted by the permanent magnets with certain pole pairs. These magnets can be placed in many ways on the rotor. The different types of radial field rotors are shown in Figure 2. The surface mounted PM rotors and surface inset PM rotors are used in the high power density machine. In the surface mounted machine, the magnets are mounted on the outer periphery of the rotor lamination which provides the highest air gap flux density as it directly faces the air gap without any interruption such as part of the rotor lamination. The drawbacks of this structure are lower structural integrity and mechanical robustness due to the snugly fitment of PM in the rotor laminations. Hence they are not preferred for the high speed applications. In the surface inset machines, the PM is placed in the grooves of the outer periphery of the rotor laminations and this provides uniform cylindrical rotor surface. This structure is mechanically robust compared to the surface mounted machines. The position sensors in the BLDC motor are meant to detect the rotor position and transform it into corresponding electrical signal. These electrical signals provide the correct commutation information for the logic circuit. Due to the correct commutation of the winding, the BLDC motor rotates continuously. Various kinds of position sensors such as electromagnetic, photoelectric and magnetic sensors are available. The hall sensor which is a type of magnetic sensor is widely used in BLDC motors because of its compact size, low price and convenient operation. Figure 3 shows the diagram of a typical hall sensor.
Figure 2: Different types of radial field rotor (a)-Surface PM (b)-
Surface inset PM (c)-Interior PM (d)-Interior PM with circumferential orientation Figure 3: Hall sensor
The working principle of BLDC motor is as that of the brushed DC
motor. In the brushed DC motor, the feedback is implemented using a mechanical commutator and brushes whereas in a BLDC motor, it is achieved using multiple feedback sensors.
ADVANTAGES OF BRUSHLESS DC MOTOR
Better speed versus torque characteristics High dynamic response High efficiency Long operating life due to a lack of electrical and friction losses Noiseless operation Higher speed ranges DISADVANTAGES OF BRUSHLESS DC MOTOR The need for an electronic speed controller (ESC) to commutate the motor. Usually extra equipment is also required to provide the throttle signal to the ESC. If the ESC is sensorless (most hobby ones are) very little starting torque is available. If the ESC is one designed to work with rotor position sensors (usually Hall effect devices) it will give good starting torque, like a brushed motor. However the sensor wiring to the ESC is often unreliable. Expensive APPLICATIONS OF BRUSHLESS DC MOTOR In recent years, the BLDC motor has achieved a sparkling expansion in the automotive, aerospace and household equipment industries due to its higher efficiency, longer lifetime, low noise and good speed-torque characteristics. In addition to the hardcore of automotive drives, the BLDC motors are used in air conditioners, wiper blades, electric doors and power seats.
Air driven and hydraulic type transmission devices are being
replaced by motor driven equipment in the aerospace industry. Special structure and position sensorless BLDC motors are widely used in the aerospace industry. In gyroscope and robotic arms, high speed centrifugal pumps and in high speed cameras with a few thousand revolutions per minute, the BLDC motor is used.
Generally in the electric appliances and compressors, induction
motors are used. But due to the low efficiency and poor power factor, the induction motors are replaced by the BLDC motors. They are used in the household appliances like vacuum cleaner, agitator, hair drier, cameras and electric fans. BLDC motors are also used as spindle motor drive in VCD, DVD and CD players