Migration From Brushed to Brushless DC Motor!

 For a very long time, DC Motors has dominated the automotive industry. However, the advancements in vehicle electronics have ushered in a new generation of electronic-controlled electric motors. The advantages provided by these cutting-edge motor control technologies have also sped up automotive OEMs' transition to Brushless DC Motors from Brushed DC Motors. Although brush and brushless DC motors are both unique in their own way, still in today's world, brushless DC motors are preferred for different uses. 

Brushless DC Motors



  

History of Automotive DC Motors  

Brushed DC Motors were traditionally used extensively in all vehicle components, including power windows, wiper systems, power steering, seating control, traction control system, etc. Brushed DC motors might accelerate to their maximum speed in just a few seconds. However, a significant disadvantage of Brushed DC Motors was wear and tear. Furthermore, it wasn't easy to control the speed of such a motor.   

These factors contributed to the widespread use of Brushless DC (BLDC) Motors in the automotive sector, along with several others. It sounds like a fascinating technological history. Before we dig further into this subject, let's review some fundamentals.  

  

Brushed Vs. Brushless DC Motors  

Both brush and brushless DC motor have two fundamental parts stator and Rotor. Although permanent magnets or electro-magnets serve as the stator in both brushed DC motors and BLDC motors, the distinction is in the commutation. Brushes are included as extra parts in a brushed DC motor.  

  

Challenges While Migrating from Brushed DC to BLDC Motors!  

The direction of the motor rotation is controlled by mechanical commutation, which is done using brushes and a copper commutator in a brushed DC motor. The transition from brushed DC motors to their brushless counterparts is fraught with difficulties. Overcoming the difficulty with commuting is the most critical problem one may encounter during the moving process. 


In comparison, a BLDC motor has several additional functions. This comprises software-level functions like soft start/stop, diagnostics ability, FOC algorithm for greater efficiency, and several others. The BLDC motor controller makes the majority of these functions possible.

  

Unlike brushed DC motors, which can only flip between two phases at a time, BLDC motors often have three steps. Therefore, three phases of the current are switched. The following commutation sequences can be used when switching to Brushless DC Motors:   


The classical and straightforward trapezoidal control   

The Space Vector PWM-enabled Advanced FOC 

 

The motor position in a BLDC motor is crucial for precise commutation. The BLDC motor controller employs Hall Effect sensors, resolvers, and encoders as feedback mechanisms. This aids in obtaining the necessary accuracy of the motor position. 

 

Integrating vector current handling takes a lot of control systems, motor knowledge, and experience. In some situations, the commutation of BLDC motors can also be done without using sensors. In these circumstances, the back EMF serves as the feedback mechanism. However, commutating BLDC Motors with the FOC algorithm is a more effective technique.  

  

Conclusion  

The preference for brushless motors over brushed motors is growing. Brushless motors are more adaptable for various applications, from conveyors to AGVs, although brushed motors are still often employed in domestic products and autos. Therefore, both brush and brushless DC motor is useful in different applications. 

Location: United States

Comments

Post a Comment

Popular posts from this blog

Brushless DC Motors For Cars

Image
Electric cars are not as completely new as you would consider. Gustave Trouve , a French inventor, invented the first electric vehicle, a tricycle, in 1881. This was made feasible by Trouve's invention of the electric motor, which allowed him to lighten the weight of the engine's parts and produce an astounding amount of energy. Since then, engineers have worked tirelessly to develop electric vehicles. Many of these efforts, particularly those involving electric cars, concentrate on improving batteries. Today, brushless DC motors for vehicles are employed for more than just tricycles and cars. Less gasoline produces fewer greenhouse gas emissions and gives drivers more incredible gas mileage. But perhaps it's time to consider what made Trouve's tricycle so groundbreaking.    While an overall approach for enhancing electric vehicles should continue to include more robust electric storage devices, such as fuel cells or batteries, one crucial component is just now comi...
Read more

Comparison Between Hydraulic, Pneumatic, and Electromagnetic Eddy Current Brakes!

Image
When it comes to industrial breaks, you will get multiple options that are available for you in the market. These brakes include hydraulic, pneumatic, and electromagnetic eddy current brakes . The best choice for you depends on the location, preferred power source, purpose, and budget.    Compared to standard brakes, these three brakes work in the opposite way. In these brakes, pressure is applied to hold the brake rather than putting pressure to engage the brake. After the removal of the power supply, the spring releases & braking force is applied to the system. It will enable spring-applied brakes to build higher torque than standard brakes. Therefore, they are very reliable and safer for loads that are in linear motion or suspended.    Hydraulic Spring Applied to Brake   Hydraulic braking systems can have massive torque. These brakes are commonly used for emergency stopping, tensioning, and keeping heavy-weight industrial equipment and off-road vehic...
Read more

Difference Between Frameless & Housed Torque Motors!

Image
Direct-drive motors constitute an appealing alternative for all applications requiring high torque at low speed to drive rotary axis types. We are aware that every application has unique requirements and limitations, nevertheless. You can choose between torque motors with or without housing in the torque motor range.   Housed Torque Motor   A brushless servomotor in complete form, a housed torque motor has the same benefits of high torque density, accuracy, and dependability as a frameless torque motors . It provides a comprehensive solution for applications where it is not desirable to integrate the motor as an active component of the machine itself. When mounted and linked, this design enables protection of the motor against water spray and dust.    Frameless Torque Motor   The frameless design is perfect for OEMs who desire simple machine integration. This torque motor is packaged with two parts: a stator, which is directly fastened to your mac...
Read more