BLDC Motor

What is a BLDC Motor| Construction, Working, and Applications

A BLDC Motor is also commonly known as a brushless DC motor. It is a highly efficient and
powerful motor that has gained popularity in various industries due to its high efficiency and
precise control. It is powered by a direct current (DC) voltage supply and does not have brushes
or a commutator.

Check out the video below by "MATLAB" to learn about BLDC Motors

https://www.youtube.com/watch?v=gNpoTPzEkco&t=591s

The difference between brushless DC motors and conventional DC motors is, that in conventional
DC motors, brushes are used to transfer the power to the rotor as they turn in a fixed magnetic
field, while brushless DC motors are commutated electronically, thereby eliminating the use of
brushes.

BLDC motors are broadly used in various applications owing to their smooth and highly efficient
operation. It also has power-saving advantages as compared to other types of motors.

Construction of BLDC Motors

In a BLDC motor, the mechanical commutator used in the conventional DC motor is replaced
with an electric switch circuit. A brushless DC Motor is a type of synchronous motor. Therefore,
the magnetic field generated by the stator and the rotor revolve at the same frequency.

A BLDC motor consists of the following parts:

● Stator

The stator of a BLDC motor is similar to the one used in an induction motor. The stator is built of
steel laminations that are stacked together with slots for winding which are axially cut. Most
BLDC motors consist of three stator windings that are connected in a star or ‘Y’ arrangement.

● Rotor

The rotor of a BLDC motor consists of permanent magnets (Samarium Cobalt (SmCo),
Neodymium (Nd), alloy of Neodymium, Ferrite and Boron (NdFeB)). The arrangement of poles
can vary according to the number of poles depending on the application of the motor.

● Position Sensors (Hall Sensors)

Since BLDC motors are commutated electronically, the windings of the stator must be energized
in a sequence and the position of the rotor must be known to precisely energize a particular set
of stator windings, to rotate the motor.

A Position Sensor or a Hall Sensor is a sensor that works on the principle of the Hall Effect. Its
function is to detect the position of the rotor and transform it into an electrical signal. These
sensors are embedded into the stator to detect the rotor’s position. Usually, three Hall sensors
are required in a BLDC motor.

Advantages of BLDC Motors

BLDC motors can be controlled using feedback mechanisms to give specifically the required
torque and rotation speed. Precision control, in turn, lessens energy utilization and heat
generation. In certain cases, where motors are powered by a battery, the precision control
enhances the battery life.

BLDC motors also offer high durability and low electric noise generation owing to the lack of
brushes. With brushed motors, the brushes and commutator wear down because of the
continuous moving contact and also produce sparks at the point of contact.

Particularly, electrical noise is a consequence of the strong sparks that happen to take place in
the areas where the brushes pass over the spaces in the commutator. Therefore, BLDC motors
are often considered preferable in applications where it is important to avoid electrical noise.

● High efficiency
● Reduced motor size
● Superior thermal characteristics
● Lightweight
● Longer lifetime
● No maintenance due to lack of brushes
● No sparking
● Steady operation
● Variable speed
● Excellent controllability
● High output power-to-size ratio
● Higher speed range
● Lower electric noise generation

Disadvantages of BLDC Motors

The cost of a BLDC motor is relatively higher when compared to a conventional brushed DC
motor. The electronic controller also elevates the overall cost of the complete setup, as in a
traditional motor. A less expensive mechanical commutation setup involving brushes is used.
When a BLDC motor is operated at low speed, slight vibrations take place during low-speed
rotation. However, the vibrations are reduced at high speed.

Due to the inherent natural vibration frequency of the BLDC motor, sometimes this natural
frequency is capable of matching or coming closer to the vibration frequency of the body or
plastic parts resulting in the occurrence of a phenomenon, known as resonance.

However, this resonance can be minimised by adjustment. The resonance phenomenon is

commonly observed in various BLDC motor-based devices.

The brushed DC motors are easy to operate as they have simple wiring. The positive terminal
is connected to the positive wire and the negative terminal is connected to the negative wire
and the motor starts rotating. However, in the case of a BLDC motor, the wiring and operation
of the motor are not that smooth and effortless. This is because of the involvement of
electronic control and its connection to all electromagnets. A large constant power range is
important for achieving high vehicle efficiency. A BLDC motor can't achieve a maximum speed
greater than twice the base speed. During the manufacturing process of the BLDC motor, it
might result in being dangerous because the large rare earth permanent magnets can attract
scattered metal objects.

In case of a vehicle crash, if the wheels spin freely and the motor is still excited by permanent
magnets, high voltages will appear at the motor terminals. This can endanger the passengers
or rescuers.

The permanent magnet can be demagnetised by applying a huge reverse magnetomotive

force and increasing the temperature. The critical demagnetization force is distinct for each
permanent magnet material. Surface-mounted motors of permanent magnets fail to achieve
high speeds. This is because of the limitation of the mechanical strength of the assembly
between the rotor yoke and the permanent magnets.

● Cost
● Limited Constant power range
● Safety
● Demagnetization
● High-Speed Performance

Applications of BLDC Motors

Considering the long list of advantages, BLDC motors can be used in numerous applications,
ranging from automotive to industrial applications. They can be used in medical equipment,
home appliances, building controls, and industrial automation. They can also be used to drive
vacuum machines. These brushless motors can also be used to spin hard disc drives.

Here, their durability keeps the drives operating dependably over the long term. The power
efficiency of these motors contributes to energy reduction in an area where this is becoming
increasingly important. Some applications that use the BLDC motors are :

● Consumer Electronics
● Transport
● Heat and Ventilation
● Industrial Engineering
● Model Engineering

Mechtex BO32(6W) is a High-Speed BLDC Motor with 9280 RPM Speed and 0.69 cNm Torque. It
offers advantages such as high reliability, efficiency, and low maintenance which makes them
suitable for industries such as Solar tracking & cleaning systems, and electric vehicles.

Servo Motor
What is a Servo Motor?

A servo motor is an electric motor that allows for precise control of angular position.
It comprises a position feedback mechanism to accurately control its motion. The
term 'servo' is derived from 'servomechanism', which is a system that uses
feedback to automatically provide a controlled power level or force to move and
hold an object at a certain position. Servo motors are typically rated in kg/cm
(kilogram per centimeter). For example, hobby servo motors might be rated at
3kg/cm, 6kg/cm, or 12kg/cm. This rating indicates the weight the motor can lift at a
specific distance. For instance, a 6kg/cm servo motor can lift a 6kg load if it is
placed 1cm away from the motor shaft. As the distance increases, the weight
capacity decreases. The position of a servo motor is controlled by an electrical
pulse, with the motor's circuitry providing feedback on its position.

Servo Motor Construction

The rotor inertia of the motors is low and has a high speed of response. The rotor of
the motor has a long length and smaller diameter. They operate at very low speeds
and sometimes even at zero speed. Servo motors find their use in applications that
require controlled rotation of a shaft, such as robotic arms, automated machines,
radio-controlled vehicles, antenna positioning, etc. They differ from conventional
motors by having an internal feedback system that monitors the shaft position and
ensures it reaches and maintains the desired position accurately.

Fig-Servo motor diagram

The internal components of a servo motor are described below:

It consists of:
○ A motor - Acts as the actuator to rotate the shaft. Can be DC, AC, or stepper
motor.
○ Amplifier - Powers the motor as per command signal from a controller.
 ○ Encoder - Acts as position sensor to detect shaft rotation in degrees or
radians.
○ Controller - Compares reference and feedback position signals to generate
correcting commands.
○ Programming inputs - Provides desired commanded position, speed, and
torque.

Servo Motor Working Mechanism

A servo motor consists of three main components:

● Controlled Device
● Output Sensor
● Feedback System
It operates in a closed loop system utilizing positive feedback to control motion and
determine the shaft's final position. The device is regulated by a feedback signal,
which is generated by comparing the output signal with a reference input signal.
The reference input signal is compared with the reference output signal, and the
feedback system produces a third signal. This third signal acts as an input to control
the device. The feedback signal is generated as long as there is a discrepancy
between the reference input signal and the reference output signal. The primary
function of the servomechanism is to maintain the system's output at the desired
value, even in the presence of noise.

Servo Motor Working Principle

The working principle of a servo motor involves the use of negative feedback. It
consists of a motor, position sensors, a controller, and an amplifier. Their power
rating varies from a fraction of a watt to a few hundred watts.
○ They are the integral components of servo systems that power applications
ranging from robotics to automation machinery.
Servo motors operate on the principle of closed loop control systems Here's a
breakdown of their working mechanism:
○ Reference Input: The desired position or velocity is set by the user through an
input signal.
○ Error Signal Generation: The controller compares the reference input with the
actual position feedback from the sensor, generating an error signal.
○ Amplification and Correction: The error signal is amplified and used to correct
the motor's position or velocity.
○ Motor Movement: Based on the corrected signal, the controller drives the
motor to move in the desired direction until the error signal becomes
negligible.
○ The controller provides commands regarding the desired rotational position.
○ The motor rotates the shaft under the power provided by the amplifier.
○ Position sensors such as potentiometers or encoders constantly monitor the
actual shaft position.
 ○ The actual position signal is compared with the reference command in the
controller.
○ Any position error or deviation is used to generate a correcting command
signal by the controller.
○ The amplifier boosts this command and provides the required power to the
motor coil to eliminate error.
○ This negative feedback loop continues till the actual position matches the set
position command.
○ The motor shaft is then held at that position against any external
disturbances.
So in summary, servo motors provide precise control over rotational motion using
position feedback for error correction in a closed-loop system.

Types of Servo Motors

They are classified as AC and DC Servo motors. The AC servomotor is further divided into
two types:

Fig-Types of Servo Motor

AC Servo Motor
AC servo motors utilize alternating current for operation. They offer high torque-to-inertia
ratios, making them ideal for applications requiring rapid acceleration and deceleration The
working principle involves controlling the amplitude and frequency of the AC input signal to
achieve precise motor control.

○ Synchronous AC Servo Motors - The Rotor is stationary and locks to the rotation
magnetic field.
○ Asynchronous AC Servo Motors - Rotor rotates at a slower speed than the rotational
field due to torque production.
 Fig-Two Phase AC Servo Motor

Below, you will find the connection diagram for a two-phase AC servo motor:

AC Servo Motor Working Principle

The stator of the Two-Phase AC Servo Motor comprises two distributed windings, positioned
90 degrees apart electrically. One winding, referred to as the Reference or Fixed Phase,
receives power from a constant voltage source. The second winding, known as the Control
Phase, is supplied with variable voltage. The control phase typically receives its power from
a servo amplifier. Rotor speed and torque are managed by adjusting the phase difference
between the control voltage and the reference phase voltage By altering this phase
difference, either leading or lagging, the rotor's rotation direction can be reversed.

Fig-The torque-speed characteristic of the two-phase AC servomotor

The descending slope indicates a higher rotor resistance, contributing to positive damping in
the motor, thereby enhancing stability. The curve maintains linearity across various control
voltages. To enhance the motor's responsiveness to light control signals, designers often
reduce the motor's weight and inertia, a concept known as the Drag Cup Servo Motor
design.

DC Servo Motor
On the other hand DC servo motors rely on direct current for power. They are renowned for
their simplicity reliability and ease of control. DC servo motors find widespread use in
applications demanding high-speed operation and precise positioning, such as robotics and
CNC machines.

Fig A- Separately Excited DC Servo motor’s connection, Fig B- armature MMF and the
excitation field MMF in quadrature in a DC machine.

DC Servo Motors are separately excited DC motors or permanent magnet DC motors.

This feature enables a rapid torque response due to the decoupling of torque and flux.
Consequently even a slight alteration in armature voltage or current yields a considerable
adjustment in rotor position or speed. It's worth noting that the majority of high-power servo
motors predominantly operate on DC power Below, you'll find the Torque-Speed
Characteristics of the motor:

Fig- Torque-Speed Characteristics of the DC Servo Motor

Based on the characteristics above, it's evident that the slope is negative. This negative
slope indicates the provision of viscous damping for the servo drive system.
Specifications of Servo Motor

Some key servo motor specifications include:

○ Voltage
○ Torque
○ Speed
○ Load Capacity
 ○ Shaft dimensions
○ Encoder resolution, etc.

Selection depends on specific application requirements.

Applications of Servo Motor

Common applications of servo motors include:

○ Industrial robotics - For controlling robotic joints and trajectory following.

○ CNC machines - Provides precise motion control in machine tools like lathes, and
milling machines.
○ 3D printers - Controls extruder head positional accuracy in additive manufacturing.
○ Semiconductor manufacturing - Critical motion requirements in lithography, and
inspection machines.
○ Automotive manufacturing - Used in welding, painting, and assembly lines for
accuracy.
○ Aerospace - Guidance and flight control systems, wing surface positioning.
○ CCTV cameras - PTZ camera positioning for surveillance applications.
○ Medical devices - Power wheelchair motors, robotic surgery systems.

Their self-correcting closed-loop design enables superior accuracy, repeatability, and

reliability in precision motion control applications.

Advantages of Servo Motor

○ High accuracy and precision - The shaft can be positioned to fractions of a degree
with encoder feedback.
○ Controlled variable speed - Speed can be accurately regulated as per command
signals.
○ Holding torque - The shaft position is held firmly even against external resisting
torques.
○ Repeatable motion - Position can be attained repeatedly to within microns of
accuracy.
○ High reliability - Feedback control eliminates error accumulation over time.
○ Smooth torque control - The amplifier regulates current to provide smooth torque
profiles.

Disadvantages of Servo Motor

○ Higher initial cost - Feedback components make them more expensive than
conventional motors.
○ Complex control - Require specialized drives, controllers, and programming for
operation.
○ Lower efficiency - Feedback circuitry and holding torque reduce efficiency compared
to motors without load-holding ability.

Difference Between Servo Motor and Stepper Motor

While both can perform precise positioning, stepper motors lack feedback control.

Parameter Servo Motor Stepper Motor

Positioning accuracy Higher accuracy of ±1° or Lower accuracy is dependent

better-using feedback on the step size without
 feedback

Speed and torque Servo amplifiers provide Speed drops sharply at lower
control controlled speed-torque torques without control
characteristics

Holding torque Can hold position firmly Requires drivers to hold

against external loads position without feedback

Cost of More expensive due to Comparatively cheaper

implementation feedback components open-loop control design