BLDC (Brush less DC) Motor Training System

Nvis 7024

Learning Material
Ver 1.1
Nvis 7024 BLDC (Brush less DC) Motor Training System
BLDC (Brush less DC) Motor Training System
Nvis 7024
Table of Contents

1. Introduction 3
2. Features 4
3. Technical Specifications 4
4. Theory 5
5. Experiments
 Experiment 1 13
Study the Running, Reversing and Braking of BLDC Motor
 Experiment 2 15
Study the Speed control of BLDC Motor using PWM control.
 Experiment 3 18
Study the Load Characteristics of BLDC Motor
 Experiment 4 20
Study the N-T Characteristics of BLDC Motor.
6. Glossary 23
7. Frequently asked questions 27
8. Warranty 30
9. List of Accessories 30

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Nvis 7024 BLDC (Brush less DC) Motor Training System
Introduction

Nvis 7024 BLDC (Brush less DC) Motor Training System is an adaptable training
system for the Electrical laboratories. It can be aptly employed for the underlying
principles for the working of a BLDC motor. In case of a brushed DC motor, feedback
is implemented using a mechanical commutator and brushes. With a in BLDC motor,
it is achieved using multiple feedback sensors. The most commonly used sensors are
hall sensors and optical encoders. The speed of BLDC motor can be control by using
PWM method, direction change and breaking system also apply through feedback
sensor.
In order to make the operation more reliable, more efficient, and less noisy the
recent trend has been to use brush less D.C (BLDC) motors. They are also lighter
compared to brushed motors with the same power output.
The product provides hands-on experiments like Speed control, Torque-Speed
Characteristics, N-I Characteristics, Direction change and Braking system etc. Thus it
also provides explicit understanding of the subject.

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Nvis 7024 BLDC (Brush less DC) Motor Training System
Features
 Provided with built in speed measurement
 Control box consist of high grade FRP material
 Brake-Drum Pulley with heat suppression facility
 Machine with Mechanical Loading Arrangement
 Exclusive and Compact Design
 Diagrammatic representation for the ease of connections
 Designed by considering all the safety standards

Technical Specifications

Mains Supply : Single Phase, 230V ±10%, 50Hz

Machine Type : BLDC
Rating : 200W
Voltage Rating : 24V
Current : 8 Amp.
Speed : 2500 rpm ±10%
Loading arrangement : Mechanical
Brake Drum/Pulley : Aluminum casted
Instrumentation power supply : 24V, 10Amp.
Digital Meters used
DC Voltmeter : 300V
DC Ammeter : 10A
Digital Tachometer : 20,000 rpm

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Nvis 7024 BLDC (Brush less DC) Motor Training System
Theory
Electrical Machine:
An Electrical machine is a common name given to devices which perform conversion
of energy from one form to another.
In electrical engineering, electric machine is a general term for machines using
electromagnetic forces, such as electrical motors, electric generator, and others. They
are electromechanical energy converters: an electric motor converts electricity to
mechanical while an electric generator converts mechanical power to electricity. The
moving parts in a machine can be rotating (rotating machines) or linear (linear
machines). Besides motors and generators, a third category often included is
transformers, which although they do not have any moving parts are also energy
converters, changing the voltage level of an alternating current.
Electric machines, in the form of generators, produce virtually all electric power on
Earth, and in the form of electric motors consume approximately 60% of all electric
power produced. Electric machines were developed beginning in the mid 19th century
and since that time have been a ubiquitous component of the infrastructure.
Developing more efficient electric machine technology is crucial to any global
conservation, green energy , or alternative energy strategy.
Depending on the type of current used for operation, Electrical machines can be
classified as AC machine and DC machine.

Classification :

When classifying electric machines (motors and generators) it is reasonable to start

with physical principle for converting electric energy to mechanical energy. If the
controller is included as a part of the machine all machines can be powered by either
alternating or direct current, although some machines will need a more advanced
controller than others. Classification is complicated by the possibilities of combining
physical principles when constructing an electrical machine. It can, for example, be
possible to run a brushed machine as a reluctance machine (without using the rotor
coils) if the rotor iron has the correct shape.
Generally, electric machines can be turned inside out, so that rotor and stator
exchange roles. All rotating electric machines have an equivalent linear electric
machine where the stator moves along a straight line instead of rotating. The opposite
linear to rotary dual is not always the case. Motors and generators can be designed
with or without iron to improve the path of the magnetic field (teeth to reduce the air
gap is a common example) and with and without permanent magnets (PM), with
different pole number etc., but still belong to different classes of machines. Electric
machines can be synchronous meaning that the magnetic field set up by the stator
coils rotates with the same speed as the rotor; or asynchronous, meaning that there is a
speed difference. PM machines and reluctance machines are always synchronous.
Brushed machines with rotor windings can be synchronous when the rotor is supplied
with DC or AC with same frequency as stator or asynchronous when stator and rotor
are supplied with AC with different frequencies. Induction machines are usually
asynchronous, but can be synchronous, if there are superconductors in the rotor
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Nvis 7024 BLDC (Brush less DC) Motor Training System
windings.

A DC motor is any of a class of rotary electrical machines that converts direct current
electrical energy into mechanical energy. The most common types rely on the forces
produced by magnetic fields. Nearly all types of DC motors have some internal
mechanism, either electromechanical or electronic, to periodically change the
direction of current flow in part of the motor.
DC motors were the first type widely used, since they could be powered from existing
direct-current lighting power distribution systems. A DC motor's speed can be
controlled over a wide range, using either a variable supply voltage or by changing
the strength of current in its field winding. Small DC motors are used in tools, toys,
and appliances. The universal machine can operate on direct current but is a
lightweight motor used for portable power tools and appliances. Larger DC motors
are used in propulsion of electric vehicles, elevator and hoists, or in drives for steel
rolling mills. The advent of power electronics has made replacement of DC motors
with AC motor possible in many applications

Electromagnetic-rotor machines:
Electromagnetic-rotor machines are machines having some kind of electric current in
the rotor which creates a magnetic field which interacts with the stator windings. The
rotor current can be the internal current in a permanent magnet (PM machine), a
current supplied to the rotor through brushes (Brushed machine) or a current set up in
closed rotor windings by a varying magnetic field (Induction machine).

Permanent magnet machines

PM machines have permanent magnets in the rotor which set up a magnetic field. The
magneto motive force in a PM (caused by orbiting electrons with aligned spin) is
generally much higher than what is possible in a copper coil. The copper coil can,
however, be filled with a ferromagnetic material, which gives the coil much lower
magnetic reluctance. Still the magnetic field created by modern Pms Neodymium
magnets is stronger, which means that PM machines have a better torque/volume and
torque/weight ratio than machines with rotor coils under continuous operation. This
may change with introduction of superconductors in rotor.
Since the permanent magnets in a PM machine already introduce considerable
magnetic reluctance, then the reluctance in the air gap and coils are less important.
This gives considerable freedom when designing PM machines.
It is usually possible to overload electric machines for a short time until the current in
the coils heats parts of the machine to a temperature which cause damage. PM
machines can in less degree be subjected to such overload because too high current in
the coils can create a magnetic field strong enough to demagnetise the magnets.

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Nvis 7024 BLDC (Brush less DC) Motor Training System

Brushed machines
Brushed machines are machines where the rotor coil is supplied with current through
brushes in much the same way as current is supplied to the car in an electric slot car
track. More durable brushes can be made of graphite or liquid metal. It is even
possible to eliminate the brushes in a "brushed machine" by using a part of rotor and
stator as a transformer which transfer current without creating torque. Brushes must
not be confused with a commutator. The difference is that the brushes only transfer
electric current to a moving rotor while a commutator also provide switching of the
current direction.
There is iron (usually laminated steel cores made of sheet metal between the rotor
coils and teeth of iron between the stator coils in addition to black iron behind the
stator coils. The gap between rotor and stator is also made as small as possible. All
this is done to minimize magnetic reluctance of the magnetic circuit which the
magnetic field created by the rotor coils travels through, something which is
important for optimizing these machines.
Large brushed machines which are run with DC to the stator windings at synchronous
speed are the most common generator in power plants, because they also supply
reactive power to the grid, because they can be started by the turbine and because the
machine in this system can generate power at constant speed without a controller. This
type of machine is often referred to in the literature as a synchronous machine.
This machine can also be run by connecting the stator coils to the grid, and supplying
the rotor coils with AC from an inverter. The advantage is that it is possible to control
rotating speed of the machine with a fractionally rated inverter. When run this way the
machine is known as a brushed double feed induction machine. "Induction" is
misleading because there is no useful current in the machine which is set up by
induction.
BLDC Motor :
Electrical equipment often has at least one motor used to rotate or displace an object
from its initial position. There are a variety of motor types available in the market,
including induction motors, servomotors, DC motors (brushed and brushless), etc.
Depending upon the application requirements, a particular motor can be selected.
However, a current trend is that most new designs are moving towards Brushless DC
motors, popularly known as BLDC motors.

This article will concentrate on the following aspects of BLDC motor design:

 Construction of the BLDC motor

 Operation of the BLDC motor
 Torque and Efficiency requirements
 Comparison with Induction and Brushed DC motors
 Selection criteria for a BLDC motor
 Motor control – Speed, Position and Torque, to be covered in Part II of this
article.
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Nvis 7024 BLDC (Brush less DC) Motor Training System
Construction:
BLDC motors have many similarities to AC induction motors and brushed DC motors
in terms of construction and working principles respectively. Like all other motors,
BLDC motors also have a rotor and a stator.
Stator :
Similar to an Induction AC motor, the BLDC motor stator is made out of laminated
steel stacked up to carry the windings. 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. This is because in the ∆ configuration, half of the
voltage is applied across the winding that is not driven, thus increasing losses and, in
turn, efficiency and torque.

Steel laminations in the stator can be slotted or slotless as shown in Figure 2. A

slotless core has lower inductance, thus it can run at very high speeds. Because of the
absence of teeth in the lamination stack, requirements for the cogging torque also go
down, thus making them an ideal fit for low speeds too (when permanent magnets on
rotor and tooth on the stator align with each other then, because of the interaction
between the two, an undesirable cogging torque develops and causes ripples in speed).
The main disadvantage of a slotless core is higher cost because it requires more
winding to compensate for the larger air gap.

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Nvis 7024 BLDC (Brush less DC) Motor Training System

Proper selection of the laminated steel and windings for the construction of stator are
crucial to motor performance. An improper selection may lead to multiple problems
during production, resulting in market delays and increased design costs.
Rotor
The rotor of a typical BLDC motor is made out of permanent magnets. Depending
upon the application requirements, the number of poles in the rotor may vary.
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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Nvis 7024 BLDC (Brush less DC) Motor Training System
Working Principles and Operation
The underlying principles for the working of a BLDC motor are the same as for a
brushed DC motor; i.e., internal shaft position feedback. In case of a brushed DC
motor, feedback is implemented using a mechanical commutator and brushes. With a
in BLDC motor, it is achieved using multiple feedback sensors. The most commonly
used sensors are hall sensors and optical encoders.
Note: Hall sensors work on the hall-effect principle that when a current-carrying
conductor is exposed to the magnetic field, charge carriers experience a force based
on the voltage developed across the two sides of the conductor.
If the direction of the magnetic field is reversed, the voltage developed will reverse as
well. For Hall-effect sensors used in BLDC motors, whenever rotor magnetic poles (N
or S) pass near the hall sensor, they generate a HIGH or LOW level signal, which can
be used to determine the position of the shaft.
In a commutation system – one that is based on the position of the motor identified
using feedback sensors – two of the three electrical windings are energized at a time
as shown in figure 4.

In figure 4 (A), the GREEN winding labeled “001” is energized as the NORTH pole
and the BLUE winding labeled as “010” is energized as the SOUTH pole. Because of
this excitation, the SOUTH pole of the rotor aligns with the GREEN winding and the
NORTH pole aligns with the RED winding labeled “100”. In order to move the rotor,
the “RED” and “BLUE” windings are energized in the direction shown in figure 4(B).
This causes the RED winding to become the NORTH pole and the BLUE winding to
become the SOUTH pole. This shifting of the magnetic field in the stator produces
torque because of the development of repulsion (Red winding – NORTH-NORTH
alignment) and attraction forces (BLUE winding – NORTH-SOUTH alignment),
which moves the rotor in the clockwise direction.

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Nvis 7024 BLDC (Brush less DC) Motor Training System

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Nvis 7024 BLDC (Brush less DC) Motor Training System

Front Panel Control

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 Nvis 7024 BLDC (Brush less DC) Motor Training System
Experiment 1
Objective:
Study the Running, Reversing and Braking of BLDC Motor
Equipments Needed:
 Connecting leads.
Circuit Diagram:

Procedure:
Note :
 First of all make sure that the earthing of your laboratory is proper and connected to
the terminal provided on back side of the panel.
 Check mains supply & MCB should be at OFF position.
 Brake switch of BLDC controller section should be off.
 Direction toggle switch of BLDC controller section should be at forward position.
 Speed control knob should be at minimum (0%) position..
 Strictly recommended belt of the loading arrangement should be free from motor
pulley at the time of starting.
 Fit proximity sensor in clamp on motor stand and keep distance between proximity
sensor and pulley (0.5-0.6) mm for accurate speed measurement

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Nvis 7024 BLDC (Brush less DC) Motor Training System
 Connect Red and Black terminal of DC Supply section (24V,10A) to voltmeter
terminal V1 & V2 respectively
 Connect Red terminal of DC supply section (24V,10A) to ammeter terminal A1
 Connect Ammeter terminal A2 to Red terminal of BLDC motor input
 Connect negative Black terminal of DC Supply to negative Black terminal of
BLDC Input .
 Connect BLDC tacho output Red and Black terminal to Red and Black terminal of
speed display respectively.
 Connect BLDC winding connection Red, Yellow and Blue to motor's terminal 1,2
and 3 respectively
 Insert 5 pin connector from motor to control panel
 Insert 3 pin connector of proximity sensor from motor’s stand to control panel.
 Check all connections once again as per connection diagram.
 Switch on the mains supply as well as MCB of the control panel.
 Switch on auxiliary toggle.
 Put brake switch ( toggle ) of BLDC controller section at on condition,
 Slightly vary the speed control knob from minimum to maximum.
 User can observe the forward rotation of BLDC motor it will rotat in clock wise
direction.
 Now vary the speed control knob from maximum to minimum position before
proceeding next step.
 Now turn the brake switch (toggle) of BLDC controller section to off position and
slightly vary the speed control knob from minimum to maximum.
 Observe motor will not run and achieve brake condition.
 Switch off the MCB.
For Reversing of BLDC motor
 Turn the brake switch (toggle) of BLDC controller section to ON position
 Now put the direction switch (toggle) of controller section to reverse position.
 Switch ON the MCB.
 Slightly vary the speed control knob from minimum to maximum.
 User can observe the forward rotation of BLDC motor it will rotat in anti-clock
wise direction.
 Switch off the MCB of control panel and mains.

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Nvis 7024 BLDC (Brush less DC) Motor Training System
Experiment 2
Objective:
Study the Speed control of BLDC Motor using PWM control.
Equipments Needed:
 Connecting leads.
 CRO (arrange from laboratory)
Circuit Diagram:

Procedure:
Note :
 First of all make sure that the earthing of your laboratory is proper and connected to
the terminal provided on back side of the panel.
 Check mains supply & MCB should be at OFF position.
 Brake switch of BLDC controller section should be off.
 Direction toggle switch of BLDC controller section should be at forward position.
 Speed control knob should be at minimum (0%) position.
 Strictly recommended belt of the loading arrangement should be free from motor
pully at the time of starting.
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Nvis 7024 BLDC (Brush less DC) Motor Training System
 Fit proximity sensor in clamp on motor stand and keep distance between proximity
sensor and pulley (0.5-0.6) mm for accurate speed measurement
 Connect Red and Black terminal of DC Supply section (24V,10A) to voltmeter
terminal V1 & V2 respectively
 Connect Red terminal of DC supply section (24V,10A) to ammeter terminal A1
 Connect Ammeter terminal A2 to Red terminal of BLDC motor input
 Connect negative Black terminal of DC Supply to negative Black terminal of
BLDC Input .
 Connect BLDC tacho output Red and Black terminal to Red and Black terminal of
speed display respectively.
 Connect BLDC winding connection Red,Yellow and Blue to motor's terminal 1,2
and 3 respectively
 Insert 5 pin connector from motor to control panel
 Insert 3 pin connector of proximity sensor from motor’s stand to control panel.
 Connect PWM outputs test point to CRO (Red terminals for PWM and Black
terminal for ground ).
 Check all connections once again as per connection diagram.
 Switch on the mains supply as well as MCB of the control panel.
 Switch on auxiliary toggle.
 Put brake switch ( toggle ) of BLDC controller section at on condition,
 Slightly vary the speed control knob from minimum to maximum.
 Motor will start to rotate in clock wise direction.
 Set the time/div. knob of CRO and use the normal mode of triggering. Adjust level
pot to fairly stable waveform. PWM wave forms which is adjusting itself
continuously to achieve particular speed, do not expect a very clean pulse
waveform.
 At higher speed user will observe disappearance of PWM waveform and continuous
low level pulse whenever that phase is "ON"
 Now vary the speed control knob from maximum to minimum position after
completion of experiment.
 Switch off the MCB and mains.

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Nvis 7024 BLDC (Brush less DC) Motor Training System
Observations :
PWM output different waveforms at various speed

Conclusion :
BLDC does not rotate up-to zero speed at certain low speeds its supply is cut off which
can be observed on CRO at test point of any phase output signal

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Nvis 7024 BLDC (Brush less DC) Motor Training System
Experiment 3
Objective:
Study the Load Characteristics of BLDC Motor
Equipments Needed:
 Connecting leads.
Circuit Diagram:

Procedure:
Note :
 First of all make sure that the earthing of your laboratory is proper and connected to
the terminal provided on back side of the panel.
 Check mains supply & MCB should be at OFF position.
 Brake switch of BLDC controller section should be off.
 Direction toggle switch of BLDC controller section should be at forward position.
 Speed control knob should be at minimum (0%) position..
 Strictly recommended belt of the loading arrangement should be free from motor
pully at the time of starting.
 Fit proximity sensor in clamp on motor stand and keep distance between proximity
sensor and pulley (0.5-0.6) mm for accurate speed measurement
 Connect Red and Black terminal of DC Supply section (24V,10A) to voltmeter
terminal V1 & V2 respectively

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Nvis 7024 BLDC (Brush less DC) Motor Training System
 Connect Red terminal of DC supply section (24V,10A) to ammeter terminal A1
 Connect Ammeter terminal A2 to Red terminal of BLDC motor input
 Connect negative Black terminal of DC Supply to negative Black terminal of
BLDC Input .
 Connect BLDC tacho output Red and Black terminal to Red and Black terminal of
speed display respectively.
 Connect BLDC winding connection Red,Yellow and Blue to motor's terminal 1,2
and 3 respectively
 Insert 5 pin connector from motor to control panel
 Insert 3 pin connector of proximity sensor from motor’s stand to control panel.
 Connect PWM outputs test point to CRO (Red terminals for PWM and Black
terminal for ground ).
 Check all connections once again as per connection diagram.
 Switch on the mains supply as well as MCB of the control panel.
 Switch on auxilary toggle.
 Put brake switch ( toggle ) of BLDC controller section at on condition,
 Slightly vary the speed control knob from minimum to maximum.
 Motor will start to rotat in clock wise direction and achieve maximum speed .
 Now slowly tight the belt and record Speed for different load currents.
Note : Maximum permissible load current rating of BLDC motor is 8 Amp.
 Record your observations into the observation table and draw the graph between
speed and load current.
 Now release the belt from pully after completion of experiment.
 Now vary the speed control knob from maximum to minimum position.
 Switch off the MCB and mains.
Observation Table :
Sr. No. Load current in ampere Speed in RPM
1
2
3
4
5

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Nvis 7024 BLDC (Brush less DC) Motor Training System
Experiment 4
Objective:
Study the N-T Characteristics of BLDC Motor.
Equipments Needed:
Connecting leads.
Circuit Diagram:

Procedure:
Note :
 First of all make sure that the earthing of your laboratory is proper and connected to
the terminal provided on back side of the panel.
 Check mains supply & MCB should be at OFF position.
 Brake switch of BLDC controller section should be off.
 Direction toggle switch of BLDC controller section should be at forward position.
 Speed control knob should be at minimum (0%) position..
 Strictly recommended belt of the loading arrangement should be free from motor
pully at the time of starting.
 Fit proximity sensor in clamp on motor stand and keep distance between proximity
sensor and pulley (0.5-0.6) mm for accurate speed measurement

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Nvis 7024 BLDC (Brush less DC) Motor Training System
 Connect Red and Black terminal of DC Supply section (24V,10A) to voltmeter
terminal V1 & V2 respectively
 Connect Red terminal of DC supply section (24V,10A) to ammeter terminal A1
 Connect Ammeter terminal A2 to Red terminal of BLDC motor input
 Connect negative Black terminal of DC Supply to negative Black terminal of
BLDC Input .
 Connect BLDC tacho output Red and Black terminal to Red and Black terminal of
speed display respectively.
 Connect BLDC winding connection Red, Yellow and Blue to motor's terminal 1,2
and 3 respectively
 Insert 5 pin connector from motor to control panel
 Insert 3 pin connector of proximity sensor from motor’s stand to control panel.
 Connect PWM outputs test point to CRO (Red terminals for PWM and Black
terminal for ground ).
 Check all connections once again as per connection diagram.
 Switch on the mains supply as well as MCB of the control panel.
 Switch on auxiliary toggle.
 Put brake switch (toggle ) of BLDC controller section at on condition,.
 Slightly vary the speed control knob from minimum to maximum.
 Motor will start to rotate in clock wise direction and achieve maximum speed .
 Now slowly tight the belt and record Speed for different load currents and applied
load on motor shaft.
 Calculate torque on belt, for this first observe the readings of spring balances.
 Now if reading of first spring balance is W1 and that of second one is W2 then the
overall force on the pulley will be W = W1-W2 (in Kg.) & calculate the torque into
the observation table for the corresponding speed by using of below formula-
T = F x R x 9.8 N/m
Where,
F = Force on the pulley
R = Radius of the pulley
Increase the load up to maximum permissible current.
Note : Maximum permissible load current rating of BLDC motor is 8 Amp.
 Record your observations into the observation table and draw the graph between
speed and Torque (N-T).
 Now release the belt from pulley after completion of experiment.
 Now vary the speed control knob from maximum to minimum position.
 Switch off the MCB and mains.

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Nvis 7024 BLDC (Brush less DC) Motor Training System
Observation Table:

Sr. Voltmeter (V) Ammeter ( I ) Spring weight Spring weight Torque(T) Speed
No. readinding in reading in (W1)in Kg. (W2)in Kg. in N-m (N) in
Volt Ampere RPM

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Nvis 7024 BLDC (Brush less DC) Motor Training System

Glossary
 Actuator: A device that creates mechanical motion by converting various forms of
energy to rotating or linear mechanical energy.
 Alternating Current (AC): The standard power supply available from local
electric utility companies.
 Ambient Temperature (AMB): The temperature of the space (air) around the
motor. Most motors are designed to operate in an ambient not to exceed 40C
(104F).
 Ampere (Amp): The standard unit of electric current. The current produced by a
pressure of one volt in a circuit having a resistance of one ohm.
 Angular velocity: The rate of change of angular position of a rotating body.
 Armature: The rotating part of a brush type direct current (DC) motor. In an
induction motor, the rotating part is called a rotor.
 Air Gap: The space between the rotating (rotor) and stationary stator member in an
electric.
 Ball Bearings: Used when high shaft load (radial or axial thrust load) capacity is
required. Ball bearings are usually used in industrial and agricultural motors.
Occasionally, roller bearings my be used on larger horsepower motors for
maximum radial load capacity.
 Breakdown Torque: the maximum torque a motor will develop under increasing
load conditions without an abrupt drop in speed and power. Sometimes called pull-
out torque.
 Brush: Current conducting material in a DC motor, usually graphite, or
acombination of graphite and other materials. The brush rides on the commutator of
a motor and forms an electrical connection between the armature and the power
source.
 Capacitance: As the measure of electrical storage potential of a capacitor, the unit
of capacitance is the farad, but typical values are expressed in microfarads (MFD).
 Capacitor: A device that stores electrical energy. Used on single phase motors.
 Capacitor Start Motor: Capacitor-Start, induction-run motor provides high
starting and break-down torque with medium starting current. Used on hard starting
applications such as compressors, positive displacement pumps, farm equipment,
etc.
 Capacitor-Start, capacitor-run: Similar to capacitor-start, but have higher
efficiency. Generally used in higher HP single phase ratings.
 Commutator: The part of a DC motor armature that causes the electrical current to
be switched to various armature windings. Properly sequenced switching creates the

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Nvis 7024 BLDC (Brush less DC) Motor Training System
motor torque. The commutator also provides the means to transmit the electrical
current to the moving armature through the brushes that ride on the commutator.
 DC Current: The power supply available from batteries, generators (not
alternators), or a rectified source used for special purpose applications.
 Duty Cycle: The relationship between operating time and the resting time of an
electric motor.
 Efficiency: The ration of the useful work performed and the energy expended in
producing it.
 Enclosure: Term used to describe the motor housing.
 End shield: Also referred to as "End Bell". The part of the motor that houses the
bearing, supporting the rotor and acts as a protective guard to the internal parts of
the motor.
 Excitation: The act of creating magnetic lines of force from a motor winding by
applying voltage.
 Field: The stationary part of a DC motor, commonly consisting of permanent
magnets. Sometimes used to describe the stator of an AC motor.
 Frequency: Number of cycles per second. Hertz (hz) has been adopted to describe
cycles per second so that time as well as number of cycles is specified. The standard
power supply in North America is 60hz. Most of the rest of the world has 50hz
power.
 Full Load Amperes (FLA): Line current (amperage) drawn by a motor when
operating at rated load and voltage on motor nameplate. Important for proper wire
size selection, and motor starter or drive selection. Also called full load current.
 Full Load Torque: The torque a motor produces at its rated horsepower and full-
load speed.
 Fuse: A piece of metal, connected in the circuit to be protected, that melts and
interrupts the circuit when excess current flows.
 Generator: Any machine that converts mechanical energy into electrical energy.
 Hertz: Frequency, in cycles per second, of AC power. Named after H.R. Hertz, the
German scientist who discovered electrical oscillations.
 High Voltage Test: Application of a voltage greater than the working voltage to test
the adequacy of motor insulation. Often referred to as high potential test or "hi-pot".
 Horsepower (HP): A measure of the rate of work. 33,000 pounds lifted one foot in
one minute, or 550 pounds lifted one foot in one second. Exactly 746 watts of
electrical power equals one horsepower.
 Impedance: The total opposition in an electric circuit to the flow of an alternating
current. Expressed in ohms.

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Nvis 7024 BLDC (Brush less DC) Motor Training System
 Induction Motor: The simplest and most rugged electric motor, it consists of a
wound stator and a rotor assembly. The AC induction motor is named because the
electric current flowing in its secondary member (the rotor) is induced by the
alternating current flowing in its primary member (stator). the power supply is
connected only to the stator. The combined electromagnetic effects of the two
currents produce the force to create rotation.
 Inertial Load: A load (flywheel, fan, etc.) which tends to cause the motor shaft to
continue to rotate after the power has been removed (stored kinetic energy).
 Kilowatt: A unit of power equal to 1000 watts and approximately equal to 1.34
horsepower.
 Kinetic energy: Energy that a body possesses by virtue of being in motion.
 Load: The work required of a motor to drive attached equipment. Expressed in
horsepower or torque at a certain motor speed.
 Moment Of Inertia: A measure of a body's resistance to angular acceleration.
 Open Circuit: A break in an electrical circuit that prevents normal current flow.
 Output Shaft: The shaft of a speed reducer assembly that is connected to the load.
This may also be called the drive shaft or the slow speed shaft.
 Polarity: As applied to electric circuits, polarity indicates which terminal is
positive and which is negative. As applied to magnets, it indicates which pole is
North and which pole is South.
 Poles: Magnetic devices set up inside the motor by the placement and connection of
the windings. Divide the number of poles into 7200 to determine the motor's normal
speed. For example, 7200 divided by 2 poles equals 3600RPM.
 Pull-Up Torque: The minimum torque delivered by a motor between zero and the
rated RPM, equal to the maximum load a motor can accelerate to rated RPM.
 Relay: A device have two separate circuits, it is constructed so that a small current
in one of the circuits controls a large current in the other circuit. A motor using the
relay opens or closes the starting circuit under predetermined electrical conditions
in the main circuit (run winding).
 Reluctance: The characteristics of a magnetic field which resists the flow of
magnetic lines of force through it.
 Resistor: A device that resists the flow of electrical current for the purpose of
operation, protection or control. There are two types of resistors-fixed and variable.
A fixed resistor has a fixed value of ohms while a variable resistor is adjustable.
 Rheostat: A continuously variable electrical resistor used to regulate current.
 Rotor: The rotating component of an induction AC motor. It is typically
constructed of a laminated, cylindrical iron core with slots of cast-aluminum
conductors. Short-circuiting end rings complete the "squirrel cage," which rotates
when the moving magnetic field induces current in the shorted conductors.
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Nvis 7024 BLDC (Brush less DC) Motor Training System
 Shaded Pole Motor: (Single Phase) Motor has low starting torque, low cost.
Usually used in direct-drive fans and small blowers, and in small gearmotors.
 Short Circuit: A fault or defect in a winding causing part of the normal electrical
circuit to be bypassed, frequently resulting in overheating of the winding and
burnout.
 Starting Torque: Force produced by a motor as it begins to turn from standstill and
accelerate (sometimes called locked rotor torque).
 Thermal Protector: A device, sensitive to current and heat, which protects the
motor against overheating due to overload or failure to start.
 Thermocouple: A pair of dissimilar conductors joined to produce a thermoelectric
effect and used to accurately determine temperature. Thermocouples are used in
laboratory testing of motors to determine the internal temperature of the motor
winding.
 Thermostat: A protector, which is temperature-sensing only, that is mounted on the
stator winding. Two leads from the device must be connected to control circuit,
which initiates corrective action.
 Torque: The turning effort or force applied to a shaft, usually expressed in inch-
pounds or inch-ounces for fractional and sub-fractional HP motors.
 Transformer: Used to isolate line voltage from a circuit or to change voltage and
current to lower or higher values. Constructed of primary and secondary windings
around a common magnetic core.
 Voltage: A unit of electromotive force that, when applied to conductors, will
produce current in the conductors.
 Watt: The amount of power required to maintain a current of 1 ampere at a pressure
of one volt when the two are in phase with each other. One horsepower is equal to
746 watts.
 Winding: Typically refers to the process of wrapping coils of copper wire around a
core, usually of steel. In a permanent magnet DC motor, the winding is the rotating
armature.

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Nvis 7024 BLDC (Brush less DC) Motor Training System
Frequently Asked Questions
Q.1 What is the basic Operation of DC Motor?
Ans: A DC motor is equipped with magnets, either permanent magnets or
electromagnetic windings that produce a magnetic field. When current passes
through the armature, also known as the coil or wire, placed between the north
and south poles of the magnet, the field generated by the armature interacts with
the field from the magnet and applies torque. In a DC motor, the magnet forms the
stator, the armature is placed on the rotor and a commutator switches the current
flow from one coil to the other. The commutator connects the stationary power
source to the armature through the use of brushes or conductive rods.
Furthermore, DC motors operate at a fixed speed for a fixed voltage and there is
no slip.
Q.2 How will you classify DC Motor?
Ans: The field coils and the armature in a shunt-wound motor are connected in
parallel, also known as shunt, formation, causing the field current to be
proportional to the load on the motor.
In series-wound motors, the field coils and armature are connected in a series
and the current flows through the field coils only.
A compound-wound motor is hybrid of both the shunt-wound and series-wound
types and features both configurations.
Q.3 How will DC Compound Machine be classified?
Ans: DC Compound Machine will be classified into two ways
 Differential Compound Machine (Long shunt and short shunt)
 Cummulative Compound Machine (Long shunt and short shunt)
Q.4 How to Make a DC Motor Spin in Reverse?
Ans: Reverse the power leads to the motor by interchange the “+”ve and “_”ve
terminals of the power supply.
Q.5 What are speed control methods of the DC motor?
Ans: Armature Voltage control and Field current control method
Q.6 What are the applications of DC Series Motor?
Ans: Large starting torque is required like in Elevators and Electric Traction. The load
is subjected to heavy fluctuations and the speed is automatically required on
sewing machines etc.
Q.7 What is the advantage of DC motors over AC motors
Ans: With the advent of the ac power generation and transmission over long distances
with fewer losses using electrical transformers, dc machines were out ruled by the
ac machines in industrial and home applications. However dc motors still exist in
the industries because of some special properties of the dc machines where ac
drives have failed to attain.

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Nvis 7024 BLDC (Brush less DC) Motor Training System
Q.8 What are the differences between DC Motor and DC Generator?
Ans: The motor uses the supplied current to excite the fields which cause rotation and
a shaft is powered to turn and do work.
In the generator, external mechanical force (such as the drive belt on a car
turning the pulley on the alternator) is applied to turn the shaft which excites the
fields and allows current to be drawn off and provides power for work.
Q.9 What is the use of Commutator in DC machine?
Ans: Commutator is the part in DC machine that makes the difference from the ac
machine. In DC machine the current flow in the armature is ac. This current is
made uni- directional with the help of commutator.
In ac machines slip rings are used to collect the armature current from the
armature and supply to the load. In DC machines this slip rings are replaced by
the split rings. Split rings consist of 2 conductor materials separated by
insulating material.
Q.10 What are the essential parts of DC machine?
Ans: Essential parts of DC Machines are given below
Field System
Armature
Commutator
Brushes
Bearings and Shaft.
Q.11 What is Critical Field Resistance?
Ans: Critical Resistance of a DC Generator is defined as the maximum field
resistance required starting the dc generator. Beyond this resistance the
generator will not able to build up the voltage (EMF) and the motor fails to
start. So care should be taken that field resistance of the dc generators should be
less than the critical resistance.
Q.12 Explain Armature reaction in DC machine?
Ans: The current that flows in the armature winding of a DC motor tends to produce
magnetic flux in addition to that produced by the field current. This effect,
which reduces the torque capacity, is called armature reaction and can effect the
commutation and the magnitude of the motor’s generated voltage.
Q.13 What is the nature of the current flowing in the armature of the DC
machine?
Ans: In the armature of the DC machine the current flow direction will be alternating
manner. This alternating current is made to unidirectional with the help of
Commutator. This is the main use of the commutator in the DC machine.

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Nvis 7024 BLDC (Brush less DC) Motor Training System
Q.14 What is the back emf ?
Ans: When the motor armature continues to rotate due to motor action the armature
conductor cuts the magnetic flux, and therefore emf are induced in them the
direction of this induced emf is such that it oppose the applied voltage therefore
this is called Back emf.
Q.15 Explain Armature reaction in DC machine?
Ans: Armature reaction is the effect of the magnetic field set up by the armature
current on the distribution of the flux under the main poles of the DC machine.
Emf will be induced in the armature of the dc machine by the Fleming's
electromagnetic induction principle (Conductor and magnetic field required to
produce emf). As the conductors of the armature are shorted current starts
flowing and this current will produce a counter magnetic filed which opposes
the main field. This effect of armature flux on the main flux so as to distort or
weaken the main field flux is called armature reaction.
Q.16 Explain how commutation in DC machine is improved?
Ans: It can be improved by using following methods:
i. By using high resistance brushes
ii. By shift of brushes
iii. By use of inter poles or commutation poles
Q.17 What will be the effect on the direction of rotation of dc motor if the supply
terminals are reversed?
Ans: No effect because direction of the rotation changes when the direction of
magnetic field changes.
Q.18 What is the nature of the current flowing in the armature of the DC
machine?
Ans: In the armature of the DC machine the current flow direction will be alternating
manner. This alternating current is made to unidirectional with the help of
Commutator. This is the main use of the commutator in the DC machine.
Q.19 What is back emf?
Ans: When the motor armature continues to rotate due to motor action the armature
conductor cuts the magnetic flux, and therefore emf are induced in them the
direction of this induced emf is such that it oppose the applied voltage therefore
this is called Back emf.

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Nvis 7024 BLDC (Brush less DC) Motor Training System
Warranty
1. We warranty the product against all manufacturing defects for 12 months from the
date of sale by us or through our dealers. Consumables like dry cell etc. are not
covered under warranty.
2. The warranty will become void, if
The product is not operated as per the instruction given in the learning material
The agreed payment terms and other conditions of sale are not followed.
The customer resells the instrument to another party.
Any attempt is made to service and modify the instrument.
3. The non-working of the product is to be communicated to us immediately giving
full details of the complaints and defects noticed specifically mentioning the type,
serial number of the product and date of purchase etc.
4. The repair work will be carried out, provided the product is dispatched securely
packed and insured. The transportation charges shall be borne by the customer.
Note:
 Measuring instruments (Voltmeter, Ammeter & Wattmeter) do not include
under warranty after first installation.

List of Accessories

 4mm Patch Cord 12” (Red) .......................................................................6 Nos.

 4mm Patch Cord 12” (Black).....................................................................5 Nos.
 4mm Patch Cord 40” (Red) .......................................................................2 Nos.
 4mm Patch Cord 40” (Yellow) ..................................................................2 Nos.
 4mm Patch Cord 40” (Blue) ......................................................................2 Nos.
 Glass Fuse 10A…………………………………………………………..5 Nos.
 Single Phase Mains chord 6A……………………………………………1 No.

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