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International Journal of Electrical, Electronics ISSN No. (Online): 2277-2626
and Computer Engineering 4(1): 114-119(2015)

Selection & Design of BLDC Motor for Different Applications

Priti S. Manware*, Md. Bashir Sheikh** and M.R. Shelke*
*Assistant Professor, Department of Electrical Engineering, PIGCOE, Nagpur, (MS), India,
**Assistant Professor, Department of Electrical Engineering, PIET, Nagpur, (MS), India,
(Corresponding author: M.R. Shelke)
(Received 04 February, 2015 Accepted 24 March, 2015)
(Published by Research Trend, Website: www.researchtrend.net)
ABSTRACT: BLDC motor is the permanent magnet synchronous motor designed to have a trapezoidal back
emf. Due to rugged construction, less control complexity, higher power density, variable speed over a wide
range and flexibility to select the rotor construction suitable for particular application, it is being viewed as
an alternative for conventional a.c. motors right from residential to commercial & aerospace systems.
Rotation of BLDC motor is achieved by energizing the stator phases in a sequence, which depends on the
rotor position. Hall sensors are used to detect the exact position of the rotor. This paper presents the review,
modeling, design & simulation of BLDC motor drive. For the purpose of demonstration, the popularly used
loads are considered. Residential application is studied with fan type load whereas for industrial application,
electric vehicle is considered. The simulation is carried out in MATLAB/ Simulink environment.
Keywords: Brushless DC (BLDC) motor, Hall effect sensor, electric vehicle, fan.
I. INTRODUCTION II. MODELING OF BLDC MOTOR
BLDC motor is simple and rugged when compared with To derive the model of BLDC motor, following
d.c. and induction machine. It is same as that of 3 phase assumptions are made [6], [7].
a.c. machine but only two phases are excited at a time. (i) Currents in rotor due stator harmonic field are
Now a days BLDC motor is preferred as compared to neglected.
brushed DC motor due to higher reliability, efficiency (ii) Iron and stray losses are neglected and damping is
and lower noise. This is observed in every field such as provided by inverter control.
in residential, industrial, automotive and household The per phase voltage relation for stator side is:
applications, because of high torque, lower maintenance vas  Rs 0 0  ias  Laa Lab Lac  ia  eas 
and variable speed control [1-3]. The advantages of v  =  0 R 0  i  + L L L  pi  + e 
BLDC motor over brushed DC motor are presented  bs   s   bs   ba bb bc   b   bs 
below. vcs   0 0 Rs  ics   Lca Lcb Lcc  ic  ecs 
(i) Armature winding on the stator makes it easy to (1)
conduct heat away from the winding. where, Rs is stator resistance/ phase, and eas, ebs, ecs are
(ii) High speed, high power to size ratio, and no arcing the induced emfs assumed to be trapezoidal. The emf
on commutation. induced/conductor is given as,
(iii) Low inertia and higher acceleration.
e = (Blv) N (2)
BLDC motor is more efficient than brushed d.c. motor
e = N (B l r ωm) (3)
because of the absence of friction due to brushes. It
e = N ф ωm
consists of 3 phase stator winding, permanent magnet
e = λ p ωm volt (4)
rotor and an electronic controller having inverter and
converter. Input a.c. power is fed to the stator winding where, N is the number of conductor in series/phase, v is
through the inverter switches as per desired phase the velocity in (m/s), l is the length of the conductor in
sequence. Rotor rotates in the direction based on (m), r is the radius of rotor bore in (m), ωm is the angular
switching sequence of the inverter [4], [5]. Position of velocity in (rad/s), B is flux density of the field in
the rotor is sensed by Hall effect sensor. Three sensors (wb/m2), in which the conductors are placed. The
are displaced from each other by 1200 electrical and are product of (Blr) denoted as ф and λ p is the flux linkage
mounted on the shaft of the rotor. When the rotor in (V.s). There is no change in the rotor reluctance with
magnetic poles pass near the hall sensors, they supply a angle because of non-salient rotor. Assuming three
high or low signal that indicates north or south poles. symmetric phases, self induced emf in the three phases
Based on combination of these are Laa = Lbb= Lcc= L and mutual inductances are Lab =
Three hall sensor signals, the exact sequence of Lba= Lca= Lbc=Lcb=M. Substituting these value of
commutation can be determined. inductance in (1).
 Manware, Sheikh and Shelke 115

vas 1 0 0 ias L − M 0 0  ia  eas

v  = R 0 1 0 i  + 0 L − M o  pi  + e 
 bs s    bs    b   bs (5)
vcs 0 0 1 ics  0 0 L − M ic  ecs

The electromagnetic torque is, =[ + + ] (N.m) (6)

ω
The instantaneous induced emf can be written as
e = f (θ )λ ω (7)
Where,
= λ [f (θ )i + f (θ )i + f (θ )i ] (N.m) (8)
The equation of motion for a simple system with inertia J, friction coefficient B and load torque Tl is,

+ = − (9)
The relation between electrical rotor speed and rotor position is
= (10)
In (5), substitute = −M, the current equations in state space form are obtained as,
= [− − ]+ (11)
= [− − ]+ (12)
= [− − ]+ (13)

From (8) & (9),

+ + = λp[f (θ )i + f (θ )i + f (θ )i ]

ω (Ө ) λ (Ө ) λ (Ө ) λ ω
= + + − −
(Ө ) λ (Ө ) λ (Ө ) λ ω
= + + − − (14)
Expressing the above relations in state space as
px = Ax + Bu (15)
where =[ ] and = [ ]

λ
− 0 0 − ( ) 0

λ
0 − 0 − ( ) 0
∴ =
λ
0 0 − − ( ) 0

λ λ λ −
( ) ( ) ( ) 0

0 0 0

0 0 0

= 0 0 0 (16)

0 0 0

0 0 0 0

Eq. (16) represents the dynamic model of a non-salient rotor type BLDC motor.
 Manware, Sheikh and Shelke 116
III. CRITERION FOR SELECTION OF MOTOR 5. Traction loads: These are the high torque loads
which may vary continuously depending upon speed,
For selection of reliable and efficient motor it is
time and the path or position of the vehicle during
essential that the conditions of service are known. It is
motion. The stiction and windage torques play
not sufficient to specify the output power in kW and
dominating roles during starting and running conditions
speed, but it is also necessary to know the following
respectively. The performance during acceleration, free-
information.
running, costing and deceleration is of importance in
(i) Torque at the shaft during running, starting and at
this type of load (Fig. 1). Popular examples are: railway
different loads.
traction, electric vehicle etc.
(ii) Accelerating torque and braking torque.
(iii) Switching frequency.
(iv) Efficiency of motor at different load.
(v) Other working requirements.
In studying the behavior of a motor selected for a
particular driven unit, one of criterion is to determine
whether the speed torque characteristic of motor suits
the requirement imposed by the speed torque
characteristic of the driven unit. Drive behavior during
the transient period of a start up, braking or speed
changeover also depends upon how the speed torque Fig. 1. Speed–time curve of a typical traction load.
characteristics of motor and the driven unit vary with
speed. Therefore it is important to study speed-torque B. Load -torque variation versus time characteristics for
characteristic to select correct motor and obtain an different types of load
economical drive. Variation of load-torque with time is of equal or greater
importance in selection of motor. This variation in
A. Speed-torque characteristics of the motor-load certain applications can be periodic and repetitive. One
mechanisms cycle of variation is called a duty cycle. Different types
The speed torque characteristics of a motor is given by of load having different load characteristics are
the relation ω= f(TL). It is defined as relationship classified as follows.
between the speed at which it is operated and the load 1. Continuous constant load: These loads operate for a
torque. Speed torque characteristics of different kinds of long time under the same condition. Examples are paper
load are divided into the following categories. making machine, centrifugal pumps, etc.
1. Load with Constant torque at all speeds: This kind 2. Continuous variable load: Hoisting winches, metal
of load offers passive torque to the motor which is cutting lathes, conveyors are the examples of continuous
essentially independent of the speed. Examples of such variable type load.
load are dry friction, cranes during hoisting, hoist 3. Pulsating load: Reciprocating pump, textile looms
winches, piston pumps operating against a constant and all machine having crank shaft come under this type
pressure head and conveyors. of load.
2. Load with linear- rising characteristics: In this 4. Short- time load: Examples are motor generator set
type of load the load torque TL rises in direct proportion for charging of batteries, servo motors used in remote
to the speed. Popular example is calendaring machine. control of drilling machine and clamping rods.
3. Load with non- linear rising (Parabola) 5. Short-time intermittent load: Crane and hoisting
characteristic: In this type of load, the load torque TL is mechanism, excavators, roll train are examples of this
proportional to the square of the speed. Windage torque type of load.
is the dominating component of this load. Different
examples are Fan, Blowers, Centrifugal pumps, IV. DESIGN OF BLDC MOTOR FOR ELECTRIC
Propellers in ships or aeroplanes, water wheels, etc. VEHICLE
4. Load with non- linear falling (Hyperbolic) In electric vehicles, the prediction of vehicle propulsion
characteristic: For such type of load, the torque TL is in accordance with power characteristics and torque
inversely proportional to the speed while power requirements of the vehicle is the key component for the
required to drive the given unit remains unchanged. design of an appropriate traction motor because the
Certain types of lathe, boring machine, milling machine speed-torque characteristics of the traction motor
and other kinds of metal cutting machine, steel mill completely determines the vehicle performance [8-11].
coilers fall under this category of loads. The parameters of vehicle load used for the design of
BLDC motor are presented in Table 1. [12].
 Manware, Sheikh and Shelke 117
Table 1: Parameters of Vehicle Load. versa. Thus if electric loading gets too high, the
Symb Description magnetic loading must decrease.
Quantity The electric vehicle application requires high power
ol
M 200 tonne Weight of vehicle density of the motor which is possible with dual air-gap
D 0.9 m Diameter of driving type axial-flux construction [2], [14]. The schematic
wheel diagrams of single air-gap and dual air-gap type
G 3% Percentage-gradient pancake motors are shown in Fig. 2 (a) & (b). The detail
R 50 N/tonne Tractive resistance design of a dual air-gap type BLDC motor for vehicle
load having parameters given in Table.1 is presented in
Γ 4 Gear ratio this paper. Some authors in the literature have suugested
Η 90% Gear transmission the use Spoke type BLDC motor for traction
efficiency applications [15].
Α 2.015 Acceleration
m= meter, N = Newton, %= percentage
A. Torque required to propel the vehicle
The tractive force necessary to propel the vehicle at the
wheels is given by
Ft = Fa + Fg + Fr (N) (17)
Where, the force required for giving linear acceleration
is, Fig. 2. Axial Flux BLDC Motor (a) single air-gap type,
Fa = 277.8 α Me (N) (18) (b) dual air-gap type.
The force required to overcome the gravitational effect
is, C. Design of dual air-gap type BLDC motor
Fg = 98MG (N) (19) The fixed parameters for the motor are calculated from
and the force required to overcome resistance to the the vehicle parameters (given above). They are
motion is, presented in Table 2.
Fr = M r (N) (20) Table 2: Fixed parameter for motor design.
The torque required to propel the vehicle is given by,
T = Ft D /η 2γ (Nm) (21) Symbol Quantity Description
where D is diameter of the wheel, η is gear efficiency
and γ is the gear ratio. Sr 1179 rpm Motor Speed
Substitution of parameter values in (17)-(21) gives, T 6000Nm Required torque
Ft = 192000 N Ri 0.15m Inside radius
T = 24000 Nm Ro 0.45m Outside radius
Assuming four number of motors, therefore torque NS 24 No. of Slot
required to be developed by each motor will be Nph 3 No of phases
T = 6000 Nm Nm 4 No. of Magnet
B. Selection of the type of BLDC motor for vehicle load pole
The construction of BLDC motor is broadly classified
into two topologies i.e. radial flux type and axial flux M = meter, rpm = revolution per minute; N-m =
type. The radial flux BLDC motor also called as Newton meter
cylindrical type motor is further classified into outer
stator type and outer rotor type. This motor is further
categorized as surface mounted type and interior
permanent magnet type [13]. The axial flux BLDC
motor also called as pancake type motor is classified as
single air-gap type and dual air-gap type.
The radial flux construction is suitable for low power
density applications. It is known that force generated in
a motor is a function of the product of flux density in
the core and the slot current. In a radial flux
construction, if the current is to be increased, more slot Fig. 3. Geometry of motor radius.
area is required to maintain constant resistive loss and
the maximum air-gap flux density decreases and vice-
 Manware, Sheikh and Shelke 118

The number of turns per slot ns is equal to

= =5 / (31)
Where, Kd is distribution factor 0.9.

Peak slot current Is is given by

= = 6806.97A (32)

Iph is phase current under the assumption that all phases

Fig. 4. Geometry Slot for dual axial flux motor. contribute equally and simultaneously to the motor. If
all phases Nph are conducting current simultaneously
When a slotted stator design is chosen there are many and back emf wave is square wave then phase current is
combinations of slots, poles, windings, and phases allow
= = 453.79 Amp (33)
to acceptable motor design. For stator design there is no
of stator slot Ns [2].
V. BLDC MOTOR FOR RESIDENTIAL
APPLICATION: FAN TYPE LOAD
= = 8 ∗ 3 = 24
(24) The radial flux type BLDC motor is of two types. One is
where, number of slots per phase Nsp is 8 and is rotor inside stator and another is rotor outside of stator.
number of phases Nph is 3. For fan type application, rotor outside stator
construction is preferred. Conventional ceiling fan uses
Number of slot per pole per phase Nspp is, induction motor which comparatively has larger size.
= =2 (25) Induction motor usually operates at high slip due to
which performance of ceiling fan is poor. BLDC motor
Nm is number of magnet poles on the rotor. is advantageous for fan type application because the
energy consumption of BLDC motor is less as
Ag is the air gap cross- sectional area given by, compared to induction motor. Also, relatively the noise
produced is less [8]-[11]. In fan, the windage dominates
( )
= ( − ) = 0.217 (26) consequently, load torque is proportional to speed
Where the magnet fraction = 0.86 squared. The speed torque relation for fan type load is
The air gap flux Фg is, [12],
= (34)
∅ = = 0.9 ∗ 0.217 = 0.117 (27)
Where, Bg is the air gap flux density. The power developed at motor shaft is given by,
= (35)
Back iron width Wbi is given by,
This load is unidirectional. It is required to run at
= = 0.323 (28) constant speed for a longer time or at several speed
Where Bmax is the maximum allowable flux density in settings or over range of speed. A general scheme of
the back iron and Bg. is the air gap flux density .The BLDC motor drive is shown in Fig 5.
outside pole pitch = 0.706m and stacking factor The 3-phase AC input is first rectified and then
= 0.9. converted to variable voltage, variable frequency AC by
The inner radius Wtbi is using 3-phase inverter. Output of the inverter is fed to
= = 0.036m (29) the stator winding. Based upon the rotor position
identified by Hall Effect sensor, the controller generates
Where the inside pole pitch = 0.2355m. appropriate switching pulses for the inverter so as to
equalize the actual speed with reference speed under
Slot bottom width Wsb is, different operating condition.
= − = 0.003 (30)
Where, inside slot pitch = 0.0391m.
 Manware, Sheikh and Shelke 119

Fig. 5. BLDC motor drive.

VI. CONCLUSION [7]. Yong-Han Kim, Bo-Suk Yang , Chang-Joon Kim,
“Noise Source Identification of Fan- Small BLDC
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