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Brushless DC motors, or "BLDC motors," are synchronous electric motors powered by DC (direct current) voltage. They are electronically commutated without brushes, hence the name "brushless motors." Brushless DC motors consist of a fixed armature along with permanent magnets which rotate, hall sensors, stator windings, rotor magnet North and South, Hall sensor magnets, an accessory shaft, and a driving end of the shaft.
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Brushless DC motors have an electronic commutation system, no brushes, and no mechanical commutators. This allows brushless electric motors to operate at higher speeds than their brushed counterparts. There can also be a different number of poles on the stator for each motor.
Most BLDC motors require a controller or driver to run. There are many different types of controls and drives designed for various applications. Many come with adjustable options, and Anaheim Automation can offer custom designs specific to a client's application. These devices are commonly referred to as "Electronic Speed Controllers," or ESCs. In a brushless DC controller or BLDC driver, either a Hall Effect Sensor or the back EMF (Electromotive Force) will be used to run the motor. The Hall Effect uses three Hall sensors within the motor to detect the position of the rotor. This method is primarily used in applications requiring speed detection, positioning, current sensing, and proximity switching. The magnetic field will change in response to the transducer which varies its output voltage. Because the sensor operates as an analog transducer, a feedback loop is created by directly returning a voltage.
Back EMF, also known as the Counter-Electomotive Force, is caused by a changing electromagnetic field. In brushless electric motors, the back EMF is a voltage which 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 current or pulsating current. At every moment, the polarity of the voltage is the reverse of the input voltage. This method is commonly used to measure the motor's position and speed indirectly.
Brush, or "brushed," DC motors use commutation brushes which periodically change the direction current flows to maintain torque. Because of the eventual wearing down of these brushes, a brush DC motor will require more maintenance and will have a shorter life than brushless DC motors. Instead of brushes, BLDC motors use hall sensors at the back end of the motor. These hall sensors output high-low pulses when they detect a change in the magnetic field. For this reason, brushless DC motors require more complex controllers, such as VSDs (variable speed drives). Additionally, since BLDC motors do not use brushes for commutation purposes, they are far more efficient, require very low maintenance, and have a longer life than brushed DC motors.
Consumer ElectronicsBrushless DC motors have monopolized many areas of the consumer electronics industry and are used in many different locations, such as in computer hard drives and CD/DVD/Blu-ray players. Brushless DC motors are also used to operate the small cooling fans located in electronic equipment. Cordless power tools also utilize BLDC motors because the need for increased efficiency of the BLDC motor allows for long periods of use before needing to recharge the battery. Furthermore, direct-drive turntables for analog audio disks use low-speed, low-power brushless electric motors.
BLDC motors have also increased in popularity among the radio controlled (RC) cars, buggies, and trucks, where sensor-type BLDC motors allow the position of the rotor magnet to be detected. Many BLDC motors feature upgrades and replaceable parts like sintered neodymium-iron-boron (rare earth magnets), replaceable motor timing assemblies, and ceramic bearings. As a result, these BLDC motors are quickly ascending to the top of the list as the preferred motor choice for electric on and off-road RC racers. BLDC motors are low-maintenance and provide high reliability and power efficiency most BLDC motors offer an efficiency rating of 80% or more.
Transportation Electric and hybrid vehicles use high power brushless DC motors that are essentially AC synchronous with permanent magnet rotors. Brushless DC motors are used in Segway and Vectrix-Maxi-Scooters also. Electric bicycles sometimes build brushless DC motors into their wheel hubs, with the stator solidly fixed to the axle and magnets attached to and rotating with the wheel. These electric bicycles have a standard bicycle transmission with pedals, sprockets, and chain that, if needed, can be pedaled along with or without the use of the brushless DC motors.
HVACIt has become a popular trend to switch from AC motors to BLDC motors (EC) because of the dramatic reduction in power needed o run them, compared with the typical AC motor. Although shaded-pole and permanent split capacitor motors were the primary fan motor of choice, many fans today are being run by BLDC motors. Some use BLDC motors simply to increase system efficiency as a whole. Certain HVAC systems use ECM motors (electronically commutated BLDC motors). In particular are the HVAC systems which feature load-modulation and/or variable-speed. BLDC motors not only have higher efficiency, but also a built-in microprocessor that allows for better airflow control, programmability, and serial communication.
Model Engineering and HobbyistsThe most popular motor option for model aircraft today are BLDC motors. The BLDC motors are available in a wide array of sizes, and have a favorable power to weight ratios. BLDC motors have transformed the market of electric-powered flight. The introduction of BLDC motors has displaced the use of almost all brushed electric motors in model aircraft and helicopters. Modern batteries and BLDC motors allow model airplanes to vertically ascend, versus gradually climb. Small glow fuel internal combustion engines that were used in the past are no comparison to the silent and clean BLDC motors.
Medical ApplicationsBrushless DC Motors have become popular amongst the medical industry for their long-lasting and low-maintenance design. Used in medical equipment, brushless DC motors have a life expectancy of 10,000 hours, whereas brushed DC motors have only a 2,000-5,000 hour lifespan. Brushless DC motors also have a top speed that is not limited by a large number of poles. It wasn't until the cost of these brushless DC Motors decreased, that they became a viable option for most medical applications. These motors are far less expensive, a primary reason they are appealing for medical equipment design.
Sleep apnea can also be treated with the help of brushless DC motors. Treatment for the disorder requires the use of Positive Airway Pressure (PAP) respirators. The PAP respirator is attached to a special breathing mask that the patient must wear to breathe through while sleeping. Within the respirator is a blower fan that pressurizes the air mask according to the patients breathing pattern. As the patient inhales, the blower fan speeds up to allow more air to reach the lungs. Conversely, when the patient exhales, the blower fan slows down to reduce the amount of air the patient breathes out.
Brushless DC motors never need to operate underneath the minimum threshold speed of the drive, so they are the perfect power source for blower fans. Furthermore, there is no risk for any sudden changes in load. Low-noise-level standards force hospital equipment to be as quiet as possible, thus making brushless DC motors a prime candidate due to how silently they operate. Brushless DC motors can operate accurately at high speeds while still maintaining low sound levels. Therefore, they can be used both in hospitals and in patients' homes. It is the absence of a commutator and brushes in brushless DC motors that removes even more of the motor noise.
These questions will help to narrow down your selection. You will then need to determine all specifications, known ones along with possible ones. For example, do you need a specific frame size, weight, power, speed, length, etc.? Each motor listed will offer specifications inherent to that particular model, such as rated voltage, rated torque, torque constant, back EMF constant, and rated power which all related to the appropriate driver. Select a driver based on the rated power, rated voltage, and the current required to run your motor given your application requirements. Keep in mind there are many different motors and driver/controllers to choose from. If you require assistance with making a selection, our applications engineers will be happy to assist you.
High cost
Additional system wiring is required to power the electronic commutation circuitry
Motion controllers/drivers electronics needed to operate brushless DC motors are more complex
Typically when the term "brushless" is used it refers to brushless DC motors, rather than referring to a general control term meaning "a feedback loop used to position the product, including brushless DC motor items." Brushless DC motors differ from other controlled motors because they are controlled by a time-based derivative commonly known to as the PID loop. Brushless DC motors must be capable of changing the velocity (rate of change of position) of the output shaft because of the time-based derivative.
Brushless DC motors can provide a more efficient, reliable, and compact motor that can be used in a variety of ways. Essentially, brushless DC motors are synchronous electric motors which are powered by a DC power source. An electric commutation circuit replaces the standard commutator and brush assembly found in the brushed DC motor. Brushless DC motors and brushed DC motors are essentially polar opposites - while the windings of brushed DC motors rotate around the rotating shaft or armature, the brushless DC motors have windings that are attached to the motor housing. The magnets of the brushed DC Motors attach to the motor housing, while brushless DC motors magnets are affixed to the rotor. 041b061a72