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A Comprehensive Review of Brushless Motors in Mechatronics

Explore the basic principles, configurations, applications, advantages, and drawbacks of brushless motors. Learn about typical motors, controllers, major specifications, and cost considerations. Find references for further exploration in mechatronics.

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A Comprehensive Review of Brushless Motors in Mechatronics

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  1. ECE 5320 MechatronicsAssignment#01: Literature Survey on Sensors and Actuators Topic: Brushless Motors Prepared by: Johnathan Nielsen Dept. of Electrical and Computer Engineering Utah State University E: johnathan.nielsen@aggiemail.usu.edu 3/11/2010

  2. Outline • Reference list • Further Exploration • Major Applications • Basic Principles • Typical Configuration • Typical Motor • Typical Controller • Examples of Applications • Major specifications • Drawbacks • Advantages • Cost ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

  3. Reference list • Mechatronics: An Integrated Approach, Clarence W. de Silva, 2005 • http://www.rctoys.com/pr/2009/05/25/all-about-brushless-motors-what-you-need-to-know/ • http://www.hpieurope.com/walk.php?lang=en&id=21 • http://en.wikipedia.org/wiki/Brushless_DC_electric_motor ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

  4. Further Exploration • There is a lot of information about brushless motors on RC Websites or Hobbyist Groups. • When searching for information it is more useful to search for “how brushless motors work”, brushless motors will just find dealers web pages to buy them. ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

  5. Major applications • R/C cars and planes. • Electric Vehicles • Hybrid Vehicles • Computer Hard Drives • CD/DVD Players • Electric Bicycle and Scooter (i.e. Segway) ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

  6. Basic Principles • Brushless motors came about to overcome the main disadvantages of standard DC motors due to the brushing mechanisms. • These reasons are: • Rapid wear out • Mechanical loading and heating • Contact bounce • Excessive noise • Arcing • Voltage ripples ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

  7. Basic Principles • Brushless motors act as an inside out standard DC motor. • Permanent-magnet rotors • Commutation by switching currents in the stator windings • This is the reverse of standard DC motors. ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

  8. Basic Principles • The stators switch polarities so that the magnets make the rotor spin • Pole count on the rotor can vary but must be more than one pole. Stator Switching Example http://www.etf.usmtu.edu.ua/spe/bldc-motor/MOTORBLDCTUT.html ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

  9. Typical Configuration ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

  10. Typical Configuration • The stators are connected to a power source, usually, a motor controller which switches the power on the stators so that the rotor spins. • The rotor can be connected just like any other standard DC motor: • Propellers • Gears • Wheels • Various other options ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

  11. Typical Motor This is a typical RC brushless motor. http://www.rctoys.com/pr/2009/05/25/all-about-brushless-motors-what-you-need-to-know/ ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

  12. Typical Controller A motor controller for a brushless motor. http://www.rctoys.com/rc-toys-and-parts/HA-X-20-PRO/RC-PARTS-SPEED-CONTROLLERS-HACKER.html ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

  13. Major Specifications • Motor Type: • Outrunner- rotor or moving part is contained within the motor. • Inrunner- rotor or moving part is the outer part of the motor. • Power- measured in watts for power consumption of the motor. ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

  14. Examples of Applications Brushless motor for an electric scooter www.gizmag.com/go/8036/picture/37999/ ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

  15. Examples of Applications Electric Scooter using Brushless Motors www.wheel.co.kr/sf1.htm ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

  16. Major Specifications • RPM/V (Kv value)- unloaded RPM at the peak voltage of the wires connected to the stators. • Example: Kv = 5700 RPM/V with Vp = 11.1V • 5700*11.1 = 63,270 RPM (unloaded) • Continuous Current- max steady state current. • Burst Current- peak current for rapid start. ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

  17. Drawbacks • More expensive than a standard DC motor. • Requires a motor controller for the stator switching which adds to the cost as well. ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

  18. Advantages • No maintenance required • Higher power to weight ratio • Many types and sizes available for all types of applications ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

  19. Cost • Cost range of brushless motors: • As low as $25.00 • Up to several hundred dollars • Cost range of motor controllers: • As low as $15.00 • Up to over $100.00 • Many combinations are possible with lots of different price ranges ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

  20. Conclusion • Brushless motors behave like DC motors but are “inside out.” • They are more convenient because they require less maintenance. • They have a higher initial cost due to manufacturing ECE5320 Mechatronics. Assignment#1 Survey on sensors and actuators

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