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Section c

Brushless DC (BLDC) motors are synchronous motors available in various configurations, utilizing Hall-Effect sensors for rotor position detection and a commutation sequence for operation. Motor selection is based on power-to-weight ratios, with specific formulas provided for efficiency, torque, and RPM calculations. The document also covers construction techniques, winding options, and gearing configurations for optimizing motor performance.

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5 views43 pages

Section c

Brushless DC (BLDC) motors are synchronous motors available in various configurations, utilizing Hall-Effect sensors for rotor position detection and a commutation sequence for operation. Motor selection is based on power-to-weight ratios, with specific formulas provided for efficiency, torque, and RPM calculations. The document also covers construction techniques, winding options, and gearing configurations for optimizing motor performance.

Uploaded by

rumishafaat
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Brushless DC (BLDC) Motors

• Brushless DC Motors are a type of


synchronous motor
– magnetic fields generated by the stator and
rotor rotate at the same frequency
– no slip
• Available in single-phase, 2-phase, and
3-phase configurations
BLDC Motor Stator
BLDC Motor Rotors
Hall-Effect

• If a current-carrying conductor is kept in a


magnetic field, the magnetic field exerts a
force on the moving charge carriers,
tending to push them to one side of the
conductor, producing a measurable
voltage difference between the two sides
of the conductor.
Hall-Effect Sensors

• Need 3 sensors to determine the position


of the rotor
• When a rotor pole passes a Hall-Effect
sensor, get a high or low signal, indicating
that a North or South pole
Transverse Sectional View of Rotor
Commutation Sequence

• Each sequence has


– one winding energized positive (current into
the winding)
– one winding energized negative (current out
of the winding)
– one winding non-energized
Torque-Speed Characteristic
Six-Step Commutation (4-pole)

• Hall-Effect Sensors
spaced 60 electrical
degrees apart
• 6 steps to complete
one electrical cycle
• Phase current
switching updated
every 60 electrical
degrees
Essential Elements of a Typical BLDC Motor
BLDC Control
CW
CCW
Brushless Motors
What you need to know.
Motor selection info.
Watts per pound of airplane weight.
– 100w/lbs = trainer/sport
– 150w/lbs = 3D aerobatics
– 200w/lbs = extreme

Watts = volts * current


– 7.4v * 10amps = 74watts
– 11.1v * 25amps = 277watts
– 22v * 50amps = 1110watts
Ex. 16oz sport airplane = 100w motor
746watts = 1 horse power
Motor formulas

Efficiency: Motor Efficiency = Pout/Pin, Pout = (Vin - Iin * Rm) * (Iin - Io)
Motor Kv: Kv = RPM / (Vin - Vloss), Vloss = Iin * Rm
Motor RPM: RPM = Kv * (V - Vloss), Vloss = Iin * Rm
Watts: Watts = V * Iin, Alternately P=I²R (P = I x I x Rm)
Stalled Motor: Istall = Vin / Rm
Torque constant: Torque constant: Kt=Kb x 1.345, Kb = Voltage constant (Volt/1000
RPM)
Torque Loss: Torque = Kt * (Iin - Io)
Termination: Wye = the number of winds you have performed, Delta = divide the number
of turns by 1.73
Watts per Horsepower: 1 horsepower = 746 watts
Kv-Rpm constant: Kv * turns = motor constant, (ex. Kv=1090 * 32T ~= 35000 so,
35000/28T ~= 1250Kv)
Motor formulas - Acronyms

Acronyms:
Rm = Resistance value of the motor, derived from the guage of wire used.
Pout = Power Out of the Motor expressed in Watts
Pin = Power In of the Motor expressed in Watts
Vin = Voltage Into the Motor
Iin = Current Into the Motor
Io = Noload Current of the Motor, derived from running a motor WOT without a prop at
varying voltages. Io can be expressed with an associated Voltage and should be.
Kv = K value or voltage constant, the expressed value where the rpm can be surmised
by a given voltage. For a 2000 Kv motor an input voltage of 10V would net
20000RPM.
Istall = The load current of a motor which is purposely stalled, hence not turning.
Kt = Torque constant (oz-In/A)
Kb = Voltage constant (Volt/1000 RPM)
Misc. motor info.
PI*(dia./2)^2) = sectional area of wire
~ Delta > Star = .578 (.562 - .526)
~ Star > Delta = 1.73 (1.78 - 1.9)

Doubling the number of winds halves Kv (rpm/volt) and doubles Kt (torque/Ampere),


Doubling stator height halves Kv, doubles Kt and (roughly) doubles maximum power.

Kv-Rpm Constant:
Example:
The 3008-32 motor has a Kv of 1090. If you take 1090 x 32 you get 34,880. If you look at the 3008-28
motor, it has a Kv of 1253.
If you take 1253 x 28 you get 35,084. Based on these 2 numbers, you can see that the constant for the
3008 size motor is right arounf 35,000.
If you take 35,000 and divie that by the number of turns, you will get the approximate Kv of the motor.
Brushless motor construction

The basic 3-phase build


Why build?

• Fun
• Cheap
• Rewarding
• Build the perfect motor for your application.
Electronic Gearing

• Divide 360deg by number of magnets then divide by 3 phases.


– This provides the degree of movement per step sequence.
• 6 cycle step sequences needed to complete 1 revolution of the magnetic
field.
– A to B / C to B / C to A / B to A / B to C / A to C

Examples:
10 magnet
360deg / 10 mag = 36deg || 36deg / 3 phase = 12deg
(12deg / step) x 6 steps = 72deg. Sequence
360deg / 72deg = 5 or 5:1 gearing

14magnet
360deg / 14 mag = 25.71deg || 25.71deg / 3 phase = 8.57deg
(8.57deg / step) x 6 steps = 51.42deg. Sequence
360deg / 51.42deg = 7 or 7:1 gearing
9-pole magnet options

9-pole stator basically two choices:


– 6 magnets (3:1 gearing)
• High RPM (Kv), low torque
• Good for Helis and ducted fans

– 12 magnets (6:1 gearing)


• Low RPM (Kv), high torque
• Larger propellers, 3D flying
12-pole magnet options
12-pole stator four choices:
LRK or DLRK wind
– 10 magnets (5:1 gearing)
• Higher RPM (Kv), lower torque
– 14 magnets (7:1 gearing)
• Lower RPM (Kv), higher torque
ABC wind
– 8 magnets (4:1 gearing)
• Higher RPM (Kv), lower torque
– 16 magnets (8:1 gearing)
• Lower RPM (Kv), higher torque
Wind techniques / options

• 9-pole stator can only be wound using ABC wind


– ABC - ABCABCABC

• 12-pole stator can be wound either ABC, LRK or DLRK.


– ABC – ABCABCABCABC (easy, need more magnets)
– LRK – A-b-C-a-B-c (high wrap count per tooth, less to wind)
– DLRK – AabBCcaABbcC (low wrap count per tooth, more to wind
12 stator pole wind types
Star or Delta connection?
Magnet polarity
Magnet installation
Check for shorts – Solder wires
9-pole stator – ABC wind
9 pole “Star” connection
9 pole “Delta” Connection
Phase A of the ABC wind 12-pole, 8 or
16-magnets
12 pole ABC “Star” Connection
12 pole ABC “Delta” Connection
Distributed LRK winding diagram
for 10 or 14 magnet poles.
Phase A, DLRK wind
LRK or DLRK

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