Brushless Motor - How they work BLDC ESC PWM

Introduction of Brushless Motor

Brushless motors are widely used in industries such as AI intelligence, automobiles, medical equipment, and industrial automation due to their long life, low noise, and high torque. Because of their different specifications and types, how to choose a brushless motor depends on It is very important to meet product performance requirements. In this article, we will introduce several principles for selecting brushless motors.

Brushless motor is also a kind of equipment commonly used in industrial production in recent years. There are many models of this equipment to choose from on the market. The models of the products are different, but the others are the same. What about suitable electrical equipment?

The structural specifications of brushless motors include planetary gearboxes, cylindrical gearboxes, parallel spur gearboxes, and worm gearboxes;

The material level is divided into metal structure and plastic structure; the power level is divided into high-power and low-power brushless motors.

1. Determine the motor’s use path, application scenario, environmental requirements, working temperature and other factors before purchasing.

2. First determine what kind of motor is needed, such as low power, high torque, low speed, noise, power, parameters and other power and performance requirements.

3. Determine the torsion stone, installation method and maintenance method of the output shaft.

4. Determine the rotation speed and reduction ratio of the input transmission shaft.

5. Select a brushless motor according to the size of the flange of the machine. If the output shaft drags the hammer insufficiently, return to 2 and re-match.

Brushless motors of different specifications and models have different usage territories and usage characteristics. Therefore, we must understand our own needs clearly before purchasing, and do not buy blindly.

Introduction to the stator part of the brushless motor

1. The stator is divided into a single-piece stator and a whole stator. The single-piece stator needs to be wound separately for each piece, and the whole nail can be directly wound as a whole. Put the frame in the slot of the stator, pay attention to the position of the outlet of the stock price, and ensure that the notch on the wiring side is placed in the middle of any plane of the stator.
2. The stator with wound wires needs to be paralleled according to the drawings. After the wires are connected, the wires should be tied (to protect the wires from being squeezed or damaged), and then the stator should be shrunk.
3. The stator that has been heat-fitted is connected to the wiring step, and the wiring needs to be carried out according to the requirements of the customer or the requirements on the drawing.
4. The stator that has been connected according to the requirements needs to be tested, and the stator is connected to the test machine to test whether the resistance and inductance meet the standard.
5. The tested stator is assembled and put into the transfer box for standby.

Introduction to the rotor part of the brushless motor

1. Glue the shaft and rotor of the brushless motor and wait for the spare.

2. Classify the magnetic steel (N grade, S grade), stick it on the rotor with glue, NSNSNS/SNSNSN, and stick the magnetic steel on the rotor steel sleeve.

3. Test the dynamic balance of the rotor (in order for the rotor to run smoothly), the tested rotor and stator are assembled, the wave pad is placed on the front cover, and the rear cover does not need a wave pad.

4. When installing the Hall, it needs to be installed according to the steering requirements of the customer or the drawing, installed on the rear output shaft of the motor, and finally debug the waveform.

5. After the motor is completely installed, it is necessary to test the whole machine with the driver, adjust the speed to the maximum, check whether the motor is running smoothly, noise, temperature rise, etc.

A brushless motor is an electric motor that uses electronic commutation instead of brushes to control the rotation of the motor. It consists of a rotor with permanent magnets and a stator with windings that are energized in a specific sequence by an electronic controller to produce rotation.

The electronic controller for a brushless motor is often called an ESC (Electronic Speed Controller), which controls the motor's speed and direction by regulating the current flow to the motor windings. The ESC measures the rotor position using sensors or back-EMF (electromotive force) feedback and uses this information to switch the current flow to the motor windings at the right time.

The switching of the current flow to the motor windings is done using a technique called PWM (Pulse Width Modulation). PWM is a method of encoding a message into a pulsing signal by varying the width of the pulses while keeping the frequency constant. In the case of a brushless motor, the PWM signal is used to regulate the amount of current flowing to the motor windings, which in turn controls the motor's speed.

BLDC (Brushless DC) motors are a type of brushless motor that uses a DC power source to drive the motor. The ESC for a BLDC motor typically has three inputs that correspond to the three phases of the motor windings, and it switches the current flow to these phases in a specific sequence to produce rotation. The sequence of switching is determined by the rotor position, which is detected using sensors or back-EMF feedback.

In summary, a brushless motor works by using electronic commutation to control the current flow to the motor windings, and this is done using an ESC that regulates the current flow using PWM signals. BLDC motors are a type of brushless motor that uses a DC power source and a specific sequence of switching to produce rotation.