ACTION RESEARCH PROJECT (ARP) REPORT

on

Pre-standardization report of Brushless DC (BLDC)

Motor

Submitted By:
Ms Neha Agarwal
Scientist ‘C’
Electrotechnical Department (ETD)

1
 POLICY, RESEARCH AND TRAINING DEPARTMENT

Our Ref: PRTD/R/5:2/AR-0052 12 Jun 2020

Subject: Action Research Project Proposal.

Ms Neha Agarwal, Sc B, ETD may please refer to her Action Research Project Proposal for
' Pre-standardization report of Brushless DC (BLDC) motor '.

She is informed that her proposal has been approved in-principle by the Assessment
Committee. A Unique Project Number ‘AR/0052’ has been assigned to her above said project,
which is required to be quoted in all future correspondences in this regard.

The officer is advised to undertake the Action Research accordingly and submit the report in
the prescribed proforma.

(Renu Gupta)
Sc F & H(PRTD)

Copy to Head ETD - to kindly ensure that administrative & financial provisions contained in
the approved guidelines on Action Research PRTD/AR/G:01/Apr 2020, as uploaded on BIS
intranet on 29 Apr 2020, are complied with.
Scanned by CamScanner
 TABLE OF CONTENT
S. no Title Page no.

1. Background 3

2. Introduction 4

3. Objective 5

4. Literature Survey 6-15

5. Relevant Data Collected 16-18

6. Summary 19

7. References 20-21

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 BACKGROUND
Brushless DC Motors or BLDC Motors have become a significant contributor of
the modern drive technology. BLDC motors offer high efficiency and
controllability and have a long operating life. They are widely used in devices that
run continuously e.g. washing machines, air conditioners, and other consumer
electronics; and more recently, they are appearing in fans, where their high
efficiency has contributed to a significant reduction in power consumption. In
future, BLDC motors may also be replacing simple brushed dc motors in several
applications.

A Brushless DC Motor is similar to a Brushed DC Motor but as the name suggests,

a BLDC doesn’t use brushes for commutation but rather they are electronically
commutated. It has a rotor with permanent magnets and a stator with windings.
Since there are no brushes in a BLDC Motor, the commutation is controlled
electronically. A Position Sensor, which is usually a Hall Sensor (that works on
the principle of Hall Effect) is generally used to detect the position of the rotor and
transform it into an electrical signal.

Brushless motors have come to dominate many applications, namely hard drives,
CD/DVD players, pumps, fans, robotic vacuum cleaners, coffee machines, mixers,
hairdryers, bread cutters and spindle drives in adjustable or variable speed
applications.

However, no Indian/international standard exist to check the quality and

performance parameters of BLDC motors.

This pre-standardization report may be utilised to set the basic minimum quality
and performance parameters including efficiency in Indian standard on BLDC
motors.

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 INTRODUCTION

Electric motor is the electro-mechanical machine, which converts the electrical

energy into mechanical energy. In other words, the devices, which produce
rotational force is known as the motor. The working principle of the electric motor
mainly depends on the interaction of magnetic and electric field. The electric
motor is mainly classified into two types- AC motor and the DC motor. The AC
motor takes alternating current as an input, whereas the DC motor takes direct
current.

Brushless DC Motors or BLDC Motors have become a significant contributor of

the modern drive technology. China is the largest consumption region of Brushless
DC Motors, with a consumption market share nearly 31% in 2017.
Europe is the second largest consumption region of Brushless DC Motors, with
consumption market share over 20% in 2017. Asia Pacific (APAC) region seems to
have good growth potential in the coming years. This growth can be attributed to
the increasing demand in China, Japan and India. The worldwide market for
Brushless DC Motor is expected to grow at a CAGR of roughly 6.8% over the next
five years, will reach 27.2 billion US$ in 2027, from 17.3 billion US$ in 2020,
according to a new GIR (Global Info Research) study. In future, BLDC motors may
also be replacing simple brushed dc motors in several applications.

BLDC motors offer high efficiency and controllability and have a long operating
life. They are widely used in devices that run continuously e.g. washing machines,
air conditioners, and other consumer electronics; and more recently, they are
appearing in fans, where their high efficiency has contributed to a significant
reduction in power consumption. Brushless motors have come to dominate many
applications, namely hard drives, CD/DVD players, pumps, fans, robotic vacuum
cleaners, coffee machines, mixers, hairdryers, bread cutters and spindle drives in
adjustable or variable speed applications.

As no National/International standards or specification/reports exist to test the

quality and performance parameters of BLDC motors, hence this pre
standardization report will be utilized to draft Indian Standard on BLDC motors.
The Indian Standard will ensure the quality production of BLDC motors and
therefore the ensuring enhanced performance of the appliances using BLDC
motors. A highly efficient BLDC motor may substantially reduce the energy
consumption of appliances and thereby improving the overall efficiency of
appliance.

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 OBJECTIVE
This project is envisaged to study the Brushless DC motor for standardization. As
stated earlier also, these motors are more efficient at converting electricity into
mechanical power than brushed motors. In addition to high efficiency, they offers
high reliability, high quality and precise speed control. Nowadays BLDC motors
are being used in various household applications like air-conditioner, ceiling fans,
washing machines, mixers etc. No Indian/international standards or
specification/reports exist to test the quality and efficiency of BLDC motors.
In view of this, following objectives were identified for this action research project:
1) Studying all possible use cases of BLDC motors in various applications in
following aspects:
a) Preferred rating for each use case
b) Possibilities of variety reduction
c) Various specification available in market
d) Various performance parameters of BLDC motors
e) efficiency of BLDC motors in different applications
f) Comparison with AC motors as per IS 996
2) studying different technologies available for position and speed control of
BLDC motor
3) determine the tests applicable on BLDC motors
4) exploring the possibility of standardization of sensor less controlled BLDC
motors

The methodology followed for fulfilling the objectives are as follows:

1) Literature Survey
2) Consultation with BLDC motor manufactures to collect various data through
online meetings

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 LITERATURE SURVEY

1. Brushless DC Motor Market Size, Share & Trends Analysis

(https://www.grandviewresearch.com/industry-analysis/brushless-dc-motors-
market)
Market analysis report as published by ‘Grand view research’ states the historical
data (2016-2019) for BLDC motors market Size, share & trends analysis by power
output (Above 75 kW, 0-750 Watts), end-use (motor vehicles, industrial
machinery), region, and segment forecasts, 2021 – 2028.
As per the report BLDC motor market size was valued at USD 17.1 billion in 2020
and is expected to grow at a compound annual growth rate (CAGR) of 5.7% from
2021 to 2028. These motors offer optimum efficiency and reliability at the same
time, which proves to be economical in the majority of applications, such as
window lifters, air conditioners, and sun-roof actuators. In terms of application,
the motor vehicle segment dominated the market with a share of 27.6% in 2020.
It is also anticipated to emerge as the fastest-growing segment at a CAGR of over
6% from 2021 to 2028.

Fig 1: BLDC motor market size, by end use, 2016-2018

In terms of power output, the 0-750 watts segment dominated the market with a
share of 47.6% in 2020 with wide usage of these products in numerous
applications, such as fans, pumps, compressors, machine tools, domestic
appliances, electric cars, HVAC applications, power tools, and automated robots.

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 0-750watts 750 W- 3kW 3kW-75kW above 75kW

Fig: 2 Global BLDC market share, by power output, 2020

The above 75kW segment is expected to witness substantial growth from 2021 to
2028. This is owing to advantages, such as better performance, in terms of
efficiency and reliability over the traditional DC motors with the same power
output rating. These BLDC motors are used for a variety of industrial
applications, such as milling, drilling, and grinding, deployed in industrial
machinery, such as the CNC machines.

2. Introduction to various motor types

IRJPEE-Assessment of BLDC Motor for EV Application Considering Vehicle
Design Strategy by Chethan S1 and Abhijith Singh S
Electric motor is the electro-mechanical machine, which converts the electrical
energy into mechanical energy. In other words, the devices, which produce
rotational force is known as the motor. The working principle of the electric motor
mainly depends on the interaction of magnetic and electric field. The electric
motor is mainly classified into two types- AC motor and the DC motor. The AC
motor takes alternating current as an input, whereas the DC motor takes direct
current.

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AC Motor
The AC motor converts the alternating current into mechanical power. The main
two types are induction motor, synchronous motor.
• Induction Motor
The machine, which never runs at synchronous speed, is called the induction or
asynchronous motor. This motor uses electromagnetic induction phenomenon for
transforming the electric power into mechanical power. According to the
construction of rotor, there are two types of an induction motor. Namely squirrel
cage induction motor and phase wound induction motor.
• Synchronous Motor
The motor, which runs at synchronous speed is known as the synchronous motor.
The synchronous speed is the constant speed at which motor generates the
electromotive force.
DC Motors
A machine that converts the DC electrical power into mechanical power is known
as DC motor. Its work depends on the basic principle that when a current carrying
conductor is placed in a magnetic field, then a force exerted on it, and torque
develops. DC motors are mainly classified into two types in the way of rotor is
powered. They are Brushed DC motors and Brushless DC motors.
Permanent Magnet Synchronous Motor (PMSM)
PMSM motors have some resemblance to BLDC motors, but are made to run by
sinusoidal signals by which lower torque ripple is achieved. Due to their
permanent magnet rotor, they also have higher torque with smaller frame size
and no rotor current, all of which are advantages over AC Induction Motors
(ACIMs).

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Comparison- Brushless DC Motor vs. Brushed Motor vs. AC Motor
Table 1
Feature Brushless DC Brushed DC AC motor as per
Motor Motor IS 996

Commutation Electronic Brushed Induction

commutation based commutation
on Hall position
sensors
Maintenance Low or no Periodic Low maintenance
maintenance maintenance

Life Longer Shorter Longer

Speed/Torque Moderately Flat Flat Non-linear

Efficiency High Moderate Moderate

Speed Range Higher- no Lower- Low

mechanical mechanical
limitation limitation
Electric Noise Low High Low
Generation

System Cost High- because of Low Low

external controller

3. What is BLDC Motor

AN885 Brushless DC (BLDC) Motor Fundamentals by Padmaraja Yedamale
A Brushless DC Motor is similar to a Brushed DC Motor but as the name suggests,
a BLDC doesn’t use brushes for commutation but rather they are electronically
commutated. It has a rotor with permanent magnets and a stator with windings.
Since there are no brushes in a BLDC Motor, the commutation is controlled
electronically. A Position Sensor, which is usually a Hall Sensor (that works on

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the principle of Hall Effect) is generally used to detect the position of the rotor and
transform it into an electrical signal.
Construction
BLDC motors have many similarities to AC induction motors and brushed DC
motors in terms of construction and working principles respectively. BLDC motors
come in single-phase, 2-phase and 3-phase configurations. Corresponding to its
type, the stator has the same number of windings. Out of these, 3-phase motors
are the most popular and widely used. Just like any other electric motor, a BLDC
motor also consists of two main parts a stator and a rotor.
• Stator
Similar to an Induction AC motor, the BLDC motor stator is made out of
laminated steel stacked up to carry the windings. The stator windings can be seen
on the outside ring of figure 1.1. Windings in a stator can be arranged in two
patterns; i.e. a star pattern (Y) or delta pattern (∆). The major difference between
the two patterns is that the Y pattern gives high torque at low RPM and the ∆
pattern gives low torque at low RPM. There are two types of stator windings
variants: trapezoidal and sinusoidal motors. Back EMF and phase current has
trapezoidal and sinusoidal variations in the respective types of motor

• Rotor
The rotor part of the BLDC Motor is made up of permanent magnets. This is
represented by the north and south poles in figure 3. Based on the application, the
number of poles can vary between two and eight with North (N) and South (S)
poles placed alternately. Increasing the number of poles does give better torque
but at the cost of reducing the maximum possible speed. Another rotor parameter
that impacts the maximum torque is the material used for the construction of
permanent magnet; the higher the flux density of the material, the higher the
torque.

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 Structure of BLDC motor
Fig: 3

• Position Sensors
Since there are no brushes in a BLDC Motor, the commutation is controlled
electronically. In order to rotate the motor, the windings of the stator must be
energized in a sequence and the position of the rotor (i.e. the North and South
poles of the rotor) must be known to precisely energize a particular set of stator
windings.
A Position Sensor, which is usually a Hall Sensor (that works on the principle of
Hall Effect) is generally used to detect the position of the rotor and transform it
into an electrical signal. Most BLDC Motors use three Hall Sensors that are
embedded into the stator to sense the rotor’s position.
The output of the Hall Sensor will be either HIGH or LOW depending on whether
the North or South pole of the rotor passes near it. By combining the results from
the three sensors, the exact sequence of energizing can be determined.

Principle Operation of Brushless DC (BLDC) Motor

The principles for the working of BLDC motors are the same as for a brushed DC
motor, i.e., the internal shaft position feedback. In the case of a brushed DC motor,

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feedback is implemented using a mechanical commutator and brushes while in
brushless motors, this is performed by sensors.
As per Lorentz force law, whenever a current carrying conductor is placed in a
magnetic field it experiences a force. As a consequence of reaction force, the
magnet will experience an equal and opposite force. In the case of a BLDC motor,
the current carrying conductor is stationary while the permanent magnet moves.
When the stator coils are electrically switched by a supply source, it becomes
electromagnet and starts producing the uniform field in the air gap. Though the
source of supply is DC, switching makes to generate an AC voltage waveform with
trapezoidal shape. Due to the force of interaction between electromagnet stator
and permanent magnet rotor, the rotor continues to rotate.
With the switching of windings as High and Low signals, corresponding winding
energized as North and South poles. The permanent magnet rotor with North and
South poles align with stator poles causing motor to rotate.
Motor produces torque because of the development of attraction forces (when
North-South or South-North alignment) and repulsion forces (when North-North
or South-South alignment). By this way motor moves in a clockwise direction.
As mentioned above also, Hall sensors give shaft position feedback to the
electronic controller unit. Based on this signal from sensor, the controller decides
particular coils to energize. Hall-effect sensors generate Low and High level
signals whenever rotor poles pass near to it. These signals determine the position
of the shaft.

3. Position and Speed Control of BLDC Motors

ICCSP-Motor Control Design for Position Measurement and Speed Control Rajesh
Kannan Megalingam, Shree Rajesh Raagul Vadivel, Bhanu Teja Pula,
Sarveswara Reddy Sathi, and Uppala Sai Chaitanya Gupta

ISSN 1424-8220 Position and Speed Control of Brushless DC Motors Using

Sensorless Techniques and Application Trends by José Carlos Gamazo-Real *,
Ernesto Vázquez-Sánchez and Jaime Gómez-Gil

IJERT BLDC Motors – A Survey of Topologies, Control & Applications by Dr. B.

Mahesh Kumar and Mr. R. Babu Ashok

IRJET Speed Control of Brushless DC Motor Using Different Intelligence

Schemes by Rubi batham, Rameshwar singh
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IJERT Position and Speed Control of Brushless DC Motors using Sensorless
Techniques: A Review by Ms. Poonam M. Yadav, Prof. Mr. Gadgune S. Y.

The control of BLDC motors can be done in sensor or sensorless mode, but to
reduce overall cost of actuating devices, sensorless control techniques are
normally used. The advantage of sensorless BLDC motor control is that the
sensing part can be omitted, and thus overall costs can be considerably reduced.
The disadvantages of sensorless control are higher requirements for control
algorithms and more complicated electronics.

Conventional Control Method Using Sensors

some of the most frequently used devices in position and speed applications are
Hall-effect sensors, variable reluctance sensors and accelerometers. Controller
needs some means of determining the rotor's orientation/position (relative to the
stator coils), such as Hall-effect sensors, which are mounted in or near the
machine’s air gap to detect the magnetic field of the passing rotor magnets.
The process of switching the current to flow through only two phases for every 60
electrical degree rotation of the rotor is called electronic commutation. The motor
is supplied from a three-phase inverter, and the switching actions can be simply
triggered by the use of signals from position sensors that are mounted at
appropriate points around the stator. These Hall switches deliver digital pulses
that can be decoded into the desired three-phase switching sequence.
In summary, permanent magnet motor drives require a rotor position sensor to
properly perform phase commutation, but there are several drawbacks when such
types of position sensors are used. The main drawbacks are the increased cost and
size of the motor, and a special arrangement needs to be made for mounting the
sensors. Further, Hall sensors are temperature sensitive and hence the operation
of the motor is limited, which could reduce the system reliability because of the
extra components and wiring.
Sensorless Control
Position sensors can be completely eliminated, thus reducing further cost and size
of motor assembly, in those applications in which only variable speed control (i.e.,
no positioning) is required and system dynamics is not particularly demanding.
control methods, such as back-EMF and current sensing provide enough
information to estimate with sufficient precision the rotor position and, therefore,
to operate the motor with synchronous phase currents. Conventional and recent
advancement of back-EMF sensing methods for the PM BLDC motors and
generators are split in two categories: direct and indirect back-EMF detection.

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4. Typical Applications of BLDC motors
EES-Review Paper- A review on recent applications of brushless DC electric
machines and their potential in energy saving by Mehdi Shirania, Abbass
Aghajania, Saeed Shabania, Jalil Jamalib

This review paper illustrates several examples of recent applications of brushless

DC machines in the oil & gas, transportation, home appliance, HVAC and
refrigeration, marine propulsion and energy production areas and the potential of
energy saving for these applications.
Many functions basically done by brushed DC motors can be fulfilled by brushless
motors but control complexity and cost restricts brushless motors from completely
replacing brushed motors.
We can categorize the applications of BLDC motor into three major types on the
basis of connected load:
• Constant load
• Varying loads
• Positioning applications
Applications With Constant Loads
These are the types of applications where a variable speed is more important than
keeping the accuracy of the speed at a set speed. In addition, the acceleration and
deceleration rates are not dynamically changing. In these types of applications,
the load is directly coupled to the motor shaft. For example, fans, pumps and
blowers come under these types of applications. These applications demand low-
cost controllers, mostly operating in open-loop.
Applications With Varying Loads
These are the types of applications where the load on the motor varies over a speed
range. These applications may demand a high-speed control accuracy and good
dynamic responses. In home appliances, washers, dryers and compressors are
good examples. In automotive, fuel pump control, electronic steering control,
engine control and electric vehicle control are good examples of these. In
aerospace, there are a number of applications, like centrifuges, pumps, robotic
arm controls, gyroscope controls and so on.

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Positioning Applications
Most of the industrial and automation types of application come under this
category. In these applications, the dynamic response of speed and torque are
important. Also, these applications may have frequent reversal of rotation
direction. Computer Numeric Controlled (CNC) machines are a good example of
this. Process controls, machinery controls and conveyer controls have plenty of
applications in this category
In summary, major applications catered by BLDC motors can be listed as:
a) Hermetic Compressors for Refrigerators and Air-conditioners
b) Heating Ventilation and Air conditioning Air Moving applications (e.g. Fan
Motors for Aircon Indoor and Outdoor Applications)
c) Household ceiling and exhaust fans
d) Hub motors for electric 2 wheelers and electric bikes
e) Elevator door opening motors
f) Health Care and surgical application Motors
g) Vacuum cleaners
h) Washing machine motors
i) Mixer grinders

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 DATA COLLECTED FROM BLDC MANUFACTURERS
Through meetings and consultation with various relevant stakeholders, real time
data was collected regarding efficiency with different applications, various
performance parameters and tests applicable, BLDC motors specification
available in market.

Efficiency of BLDC motor with different applications:

Table 2

Sl Application Output Efficienc Remarks

No. y%

1. Hermetic Compressor 35- 81-90 Estimated

motor for Refrigerators 120W

2. Hermetic Compressor for 400- 88-92 Estimated

Aircon 1000W

3. Split Aircon Indoor Unit 30W 70 Estimated

Fan Motors

4. 60W 70 Estimated
Split Aircon Outdoor Unit
Fan Motors

5. 1.5-2W 60 Estimated
Frost Free Refrigerator
Freezer Fan Motor

6. 20-25W 65-70 Estimated

Household ceiling

7. Condenser cooling Motors 10-30W 65-70 Estimated

in Chest Freezers

8. Aircooler Motors 75W 70-80 Estimated

9. Vacuum Cleaners 350W 75-80 Estimated

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 10. Washing Machine Motors 120W 75 Estimated
Top Load

11. Washing Machine Front 200- 75-80 Estimated

load 400W

12. Mixer Grinders 500W 70 Estimated

13. exhaust fans 20W- Estimated

180W

Various Specification Available in Market

Table 3
Rated Power/W 1200W 1500W 1800W 2200W

Rated Voltage 48/60/72 V DC 48/60/72 V DC 60/72 V 60/72 V

DC DC

Unload current/A <6.0/5.4/4.5 A <6.0/5.4/4.5 A <6.0/5.5A <6.5/6.0 A

No load speed/rpm 3500 4100 4500 4800

Rated torque/N.m 4.0 5.2 6.0 7.2

Rated speed/rpm 2850 3000 3200 3550

Rated current/A <32.0/25.0/21.0 <39.0/31.5/26.0 <37.5/31.5 <46.0/38.0

Efficiency >82% >82% >83% >84%

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Various Performance Parameters of BLDC Motors
a) Maximum torque delivery capacity
b) Torque Density (Torque delivery per unit motor volume)
c) Peak current drawn by the motor with the risk of demagnetization of
permanent magnets.
d) Torque Constant (torque delivered per unit current drawn)
e) Back EMF constant (Voltage produced per 1000 rotor revolutions)
f) Efficiency of the motor
Various Tests Applicable on BLDC Motor
a) Voltage/current
b) Input/output power
c) Efficiency at rated and fractional loads
d) Power factor
e) Back EMF Measurement
f) Speed Torque characteristics
g) Temperature rise test
h) Demagnetization of test
i) Noise
j) Vibration
k) Harmonic measurement
l) Environment Condition tests
m) Phase sequence determination
n) Hall sensor error positioning; accuracy

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 SUMMARY
In conclusion, BLDC motors have advantages over brushed DC motors and
induction motors. They have better speed versus torque characteristics, high
dynamic response, high efficiency, long operating life, noiseless operation, higher
speed ranges, rugged construction and so on. Also, torque delivered to the motor
size is higher, making it useful in applications where space and weight are critical
factors. With these advantages, BLDC motors find wide spread applications in
automotive, appliance, aerospace, consumer, medical, instrumentation and
automation industries. The Indian standard will ensure the quality production of
BLDC motors and therefore the ensuring enhanced performance of the appliances
using BLDC motors. A highly efficient BLDC motor may substantially reduce the
energy consumption of appliances and thereby improving the overall efficiency of
appliance.

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 REFERENCES
• Chethan S1 and Abhijith Singh S “Assessment of BLDC Motor for EV
Application Considering Vehicle Design Strategy” International Research
Journal of Power and Energy Engineering Vol. 3(2), pp. 118-124, November,
2017
• Padmaraja Yedamale “Brushless DC (BLDC) Motor Fundamentals” AN855
2003 Microchip Technology Inc.
• Rajesh Kannan Megalingam, Shree Rajesh Raagul Vadivel, Bhanu Teja
Pula, Sarveswara Reddy Sathi, and Uppala Sai Chaitanya Gupta “Motor
Control Design for Position Measurement and Speed Control” International
Conference on Communication and Signal Processing, April 4-6, 2019
• José Carlos Gamazo-Real *, Ernesto Vázquez-Sánchez and Jaime Gómez-
Gil “Position and Speed Control of Brushless DC Motors Using Sensorless
Techniques and Application Trends” International Journal of Engineering
Research & Technology (IJERT) ISSN: 2278-0181 Vol. 8 Issue 01, January-
2019

• Dr. B. Mahesh Kumar and Mr. R. Babu Ashok “BLDC Motors – A Survey
of Topologies, Control & Applications” International Journal of Engineering
Research & Technology (IJERT) ISSN: 2278-0181 Vol. 5 Issue 03, March-
2016
• Rubi batham, Rameshwar singh “Speed Control of Brushless DC Motor
Using Different Intelligence Schemes” International Research Journal of
Engineering and Technology (IRJET)-ISSN: 2395-0056 Volume: 04 Issue:
10 | Oct -2017
• Ms. Poonam M. Yadav, Prof. Mr. Gadgune S. Y “Position and Speed Control
of Brushless DC Motors using Sensorless Techniques: A Review”
International Journal of Engineering Research & Technology (IJERT) Vol.
8 Issue 01, January-2019
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review on recent applications of brushless DC electric machines and their
potential in energy saving” Energy Equipment and Systems, 2015
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n-to-electric-motors

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