Tag: bldc motor

Mechanical vibration and noise are key factors when designing a brushless DC motor. Uncontrolled noise and vibration often cause rapid system degradation, affect efficiency, and adversely affect wear on this control system. This is especially true of sensitive medical equipment, robotics, commercial systems, and handheld devices. Noise and vibration can have a significant impact on system performance, reliability, and operating costs. For handheld devices, vibration can be transferred to the user, causing safety concerns and pressure injuries. Whether in a hospital, laboratory or office, excessive noise from motors running around people can be a health hazard.

ATO.com is a one-stop online store for industrial automation equipment/components. There are many types of products in our website. Such as motors, motors controls, passives components, tools , industrial equipments, etc. In this article, some hot selling products on ATO.com will be introduced.

BLDC consists of motor and drive, which is a typical mechatronic product. It is composed of permanent magnet rotor, multi-pole winding stator and position sensor. Brushless DC motors (BLDC) feature high efficiency and excellent controllability, and are widely used in many applications. The BLDC motor has power-saving advantages relative to other motor types. Motor above 5000 rpm is a high speed motor, that is, brushless DC motor above 5000 rpm can be called high speed brushless DC motor. 

In addition to the brushless DC motor is often used in industrial automation, we often see its application in electric vehicles. And what we want to introduce today is an infrastructure that it uses in electric vehicles.

To let ATO BLDC motor drive fully perform its speed control function, it is very important for you to make sure that the hall sensor is properly connected to the driver. In this blog we’re gonna illustrate the correct wiring steps.

Brushless DC motor is composed of motor body and driver, which is a typical mechatronics product. High speed brushless motor refers to the motor without brush and commutator (collector ring), also known as the motor without commutator. Brushless DC motor is widely used in automobiles, tools, industrial control, automation and so on. We also need to know how to use it. Taking ATO's brushless DC motor as an example, this paper describes how to use external switch button to reverse rotation, stop the motor, and external potentiometer to speed the brushless DC motor.

The speed control methods of the BLDC motor controller include self-contained potentiometer speed control, external potentiometer speed control, and external analog signal speed control (0 ~ 5V). Different occasions and distances can use different speed control mode, which is one of the features of our brushless DC motor kit. Now what we want to introduce is how to use the 5V analog signal to control the speed of the DC brushless motor.

All motors with external characteristics of DC motors that use electronic commutation are collectively referred to as brushless motors. Due to the emergence of brushless DC motors, the strict boundaries between AC-DC speed regulation systems have been broken. In the history of the development of brushless motors, there have been two major structures of brushless motors with great difference, which are brushless DC motors and AC commutated brushless motors.

The electric energy of the bldc motor is finally supplied in DC mode. Based on the method of obtaining DC power, there are two main implementation methods for brushless DC motors: AC-DC-AC control system and DC-AC control system, which are known as square wave.

Hall sensor can also be called as the Hall encoder. The Hall sensor in the brushless DC motor controller is used to detect the rotation speed of the bldc motor. In some applications, it is necessary to adjust the speed of the brushless DC motor, and to ensure that the bldc motor remains unchanged at a certain speed, so it is necessary to add a Hall sensor that detects the speed for feedback. The brushless DC motor controller will output different control pulse signals according to the detected speed value, and finally achieve the purpose of quickly adjusting the speed of the brushless DC motor.

If the brushless dc motor without Hall sensor is broken, it cannot be replaced with the brushless dc motor with Hall sensor. The hardware drive circuit of these two motors is different, so is the program code, thus the bldc motors will not work after the replacement. ATO will tell you why.

1. The hardware circuit of a motor with Hall sensor and a motor without Hall sensor is different.

For a three-phase bldc motor, a brushless dc motor with Hall sensors has eight wires: 3 three-phase motor wires, 3 Hall wires, and 2 Hall power wires. There are three Hall chips inside the brushless dc motor with Hall sensor. When the motor is working, the real-time position of the rotor can be displayed to the control board in the form of waveform. Based on the waveform, the position of the rotor and the rhythm to start the brushless dc motor will be determined by the control board.

Nowadays, many automation equipment manufacturers have begun to pay attention to brushless DC motors. They want to use brushless DC motors to replace induction motors, stepper motors, etc., which have many defects such as low efficiency, high noise, and high power consumption. Recently, ATO has also received many inquiries from new and old customers: Do BLDC motors and brushed DC motors both rotate when powered? Actually not. Brushless DC motors must be equipped with corresponding controllers to rotate. This is determined by the structural principle of the brushless dc motor.

The brushless DC motor is a device that converts electrical energy into mechanical energy. By consuming electrical energy, mechanical energy can be obtained to achieve certain needs. What are the applications of BLDC motors? Brushless DC motors can be used in the small home appliance industry. The most common electric fan is to use brushless DC motors to convert electrical energy into mechanical energy to turn the electric fan, bringing us coolness. In addition, lawn mowers in the garden industry and electric drills in the power tool industry all work with brushless motors.

Brushless dc motor
The brushless DC motor is composed of a motor body and a brushless motor driver. It is a typical mechatronics product. Because the brushless DC motor runs in a self-control mode, it will not add a start winding to the rotor like a synchronous motor started under heavy load under variable frequency speed regulation, nor will it cause oscillation and loss of step when the load changes suddenly. The permanent magnets of small and medium-capacity brushless DC motors now mostly use high magnetic energy level rare earth neodymium iron boron (Nd-Fe-B) materials.

Stepper motor
A stepper motor is a motor that converts electrical pulse signals into corresponding angular or linear displacements. Every time a pulse signal is input, the rotor rotates an angle or moves forward. The output angular displacement or linear displacement is proportional to the number of input pulses, and the speed is proportional to the pulse frequency. Therefore, the stepper motor can be called the pulse motor.

Working Principle of BLDC Motor
The BLDC motor is mainly composed of the motor body, position sensor, electronic commutation circuit and driver. The motor body is similar in structure to a permanent magnet synchronous motor, but it has neither cage windings nor other starting devices. The stator windings are generally made into multiple phases (three-phase, four-phase, five-phase and so on). The rotor is composed of permanent magnet steel according to a certain number of pole pairs (2p=2, 4...). In a brushless DC motor, the armature winding is arranged on the stator, and the permanent magnet poles are arranged on the rotor. The position of the armature winding of each phase of the stator relative to the magnetic field of the permanent magnet of the rotor is sensed by the rotor position sensor electronically or electromagnetically. Moreover, it uses its output signal to drive the corresponding power switch transistor connected with the armature winding through an electronic conversion circuit according to a certain logic program, and commutate the current switch to the corresponding armature winding. With the rotation of the rotor, the rotor position sensor continuously sends out signals, causing the armature winding to be continuously energized in sequence, and the energization state is constantly changed. As a result, the direction of the current flowing in the coil conductor under a certain magnetic pole is always the same, and the rotor keeps running.

ATO provides customized 100W to 15kW high torque brushless DC motors with reasonable price. They come with different square flange size, rated speed from 1000rpm to 3000rpm, work at 12 volt, 24 volt, 48 volt, 96 volt voltage. Matched BLDC controller is available here which has powerful functions to meet your needs. The price of our high torque BLDC motors is listed as table below, check and buy one you desired right now, motor parameters are customizable according to your requirements.

Generally, the wiring principle of brushless DC motor is basically similar. Next, we choose the model ATO-BLDC-40030 of ATO high torque BLDC motor and its matching controller ATO-BLDC-TH-G as examples to show you how to connect the motor to the controller and make the motor rotate.

Brushless DC motor (BLDC) replaces the mechanical commutator with electronic commutator, just because of the electronic commutator, the BLDC motor needs a controller to drive the circuit. ATO BLDC motor not only has a speed regulation performance as the DC motor, but also has the advantages of simple structure, no commutation spark, reliable operation and easy maintenance as the AC motor, so it’s widely used in industrial equipment, instrumentation, household appliances, robots, medical equipment and other fields. The commutation circuit of BLDC motor consists of two indispensable parts: drive and control. Particularly, the two parts are integrated into a single ASIC for low power circuit.