High torque BLDC motor are used in applications that require precision and reliability. In some cases, dependency on sensors can affect the performance of these motors.
A BLDC motor uses permanent magnets in its rotor to create magnetic fields. Its stator is made up of stacked steel laminations with windings arranged in a star or delta pattern.
Efficiency
High torque BLDC motors can be used for many applications requiring a combination of high speed and power. These motors have a robust dynamic speed response, require less maintenance and use a smaller volume than other DC motors. They are ideal for use in industrial automation, electric vehicles, robotics, and other mobile systems.
The radial or axial flux motor topology is based on permanent magnets that impose the magnetic field in either a radial or axial direction. The axial direction is often preferred for higher speed applications. The radial or axial direction of the magnetic field is determined by a complex relationship between the polarity of the magnets and their coercivity. This translates to the motor having different hysteresis behavior in a radial or axial direction depending on its magnet configuration and material permeability.
To evaluate the thermal response of this high torque BLDC motor, a high-resolution temperature sensor (NTC thermistor B57861S0103A039, TDK Electronics AG, Munich, Germany) was directly installed on the stator winding coil using a thermally conductive epoxy (EP42HT-2AO-1 Black, Master Bond Inc, Hackensack, NJ, USA). The motor drive High torque BLDC motor board was mounted on an aluminum plate with a low-profile CPU cooler (C7 Cu, Cryorig, New Taipei City, Taiwan).
In order to measure efficiency and loss across the full range of current setpoints, both 24 V and 36 V operating conditions were tested. As illustrated in Figure 6, the EVEREST motor driver exhibited stable performance, with peak temperatures never exceeding their specified limit. The temperature data also demonstrates that momentarily overpowering the motor for short periods is acceptable as long as the resulting instantaneous thermal energy does not exceed the safety limit.
Load Capacity
High torque BLDC motors can deliver a large amount of mechanical power to generate rotational force. This capability can be a major benefit for embedded applications with speed, torque and feedback requirements. They also offer a high efficiency rate, meaning they convert a high percentage of electrical energy into mechanical output power and consume less electric current than other motor types.
The RPX series of high-torque BLDC motors from maxon is designed for embedded applications that require high power density and fast speeds. They feature a compact, small-frame design that enables them to fit into tight spaces. They are available in a wide range of sizes with different rated torques and frame sizes to suit various applications, ensuring there is an ideal solution for each individual application.
In most applications, the motor size is determined by a physical space constraint rather than performance characteristics. For example, a customer with an automotive industry power seat application needed high torque at high speeds normally available only in larger-frame motors. They chose to use the RPX32 with a 32 mm diameter frame which allowed it to fit into their design and deliver 175 m-Nm of continuous torque at 11,000 RPM.
Another consideration is whether the motor needs to be able to provide dynamic acceleration and deceleration to meet system requirements. This type of requirement High torque BLDC motor company often calls for a small frame BLDC motor with high overload capacity. In such cases, the BRX series of high-torque flat motors from maxon provides a powerful and reliable solution.
Noise
When a motor is operating, it creates electromagnetic noise from magnetic fields, mechanical friction, and electrical current flow. These factors contribute to the sound level of a motor and are an important consideration when selecting the right motor for your application.
High torque BLDC motors are less noisy than their brushed DC motor counterparts. This is due to the fact that brushless motors do not use sliding contacts for commutation and therefore have less friction. Moreover, they do not produce sparks during commutation which can cause damage to other motor components such as bearings and the stator windings.
Instead, the rotor of a BLDC motor is surrounded by a set of coils made of coiled copper wire that interact with permanent magnets. When an electric current is passed through these coils, it produces a magnetic field that rotates the rotor. The commutation of the coils is controlled by the Hall position sensor located on the stator.
The resulting motor has a lower noise output, and because it does not require brushes for commutation, it is also less maintenance intensive than its brushed DC counterpart. Moreover, the lack of sliding contacts and commutating sparks extends the lifespan of the motor.
BLDC motors are ideal for applications that require precise speed regulation. For instance, in robotic applications, it is necessary to control the speed of a motor during delicate tasks. Similarly, manufacturing processes depend on the consistency of speed to ensure quality products. A BLDC motor can be easily adjusted to the desired speed with the help of a control system.
Maintenance
A High torque BLDC motor is an electrical motor that uses electronic commutation instead of brushes to supply power to the windings in the rotor. This eliminates the need for mechanical contact between the rotor and commutator, and allows for higher efficiency than traditional DC motors. The rotor and stator are the two critical components in this type of motor, and they both play a vital role in ensuring optimal performance. The rotor is made up of permanent magnets, while the stator has coils that produce a magnetic field when current flows through them.
The commutator is a crucial part of the motor, as it splits the electric current between the rotor and the stator to ensure that both sides receive the correct amount of energy at all times. A high-quality commutator is designed to have a smooth, even surface for optimal performance. In addition, the commutator should be able to tolerate high temperatures and high currents for maximum durability.
While BLDC motors do not have brushes, they require regular lubrication to reduce friction between the rotor and other parts of the motor. Using manufacturer-recommended lubricants and following the specified lubrication schedule will help to reduce wear, prolonging the motor’s lifespan and increasing its overall performance. Brushless motors also do not generate dust, making them an excellent choice for clean or sterile environments.