and manufacturers of BLDC
The electric motors
market divided into two types: AC and DC, we concern about the DC one. In order
to obtain the right DC motor for your purpose there are some factors must be
taken into considerations and that will be discussed in the following sections.
Every motor has its specifications and these divided into general and electrical specifications.
Brushless DC motor
a.k.a. (BLDC) is a very important product for those who prefer less noise
operation, high speed, less maintenance, more efficient motor and high starting
torque. BLDC has electronic driver to get the rotor position in order to make
the right commutation.
discussing the design considerations in the (previous chapters), we will
discuss the manufacturing process and the cost for each stage in the process
2. BLDC layout
BLDC motor consists of four main components
(Electronic and mechanical):
1- Stator (stationary part)
Stator starts out with steel laminations
(Lam) which are being manufactured with low loss electrical steel with high
quality by using a stamping die. The stamping die type is high maintenance, low
volume and low cost. In the manufacturing process, choosing the right lam and
stamping die is an economical decision.
2- Rotor (Movable part)
Rotor consists of three elements: The
shaft, the hub which the PM is hanged with, permanent magnets, and the bearings.
3- Electronic commutation (instead of mechanical commutation)
Consists of four major elements:
4.1 The inverter which include six transistors and these
is the most expensive part, because they will have high power ratings.
4.2 The logic circuit which may has a DSP (Digital signal
processing) to decode the rotor position and generate the right PWM.
4.3 Heat sink and thermal management hardware to control
the ambient temperature.
4.4 AC capacitors to be used as filters for the conversion
from the input voltage to a DC voltage.