Introductory Course on Design of BLDC Motors

Ali Jamali Fard

https://ComProgExpert.com
https://www.youtube.com/c/ComProgExpert
Course objective

Induction Motor BLDC Motor

Pout  1HP  0.75kW

Pout  1HP  0.75kW
Speed  1500 RPM
Speed  1500 RPM
OSDmax  125mm
OSDmax  125mm
Lstk ,max  70mm
Lstk ,max  70mm
Vt  400V
VDC  500V
d  72.1%
d  72.1%
PFd  0.8

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 2

Motor Nameplate

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 3

IE efficiency classes

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 4

IE efficiency classes

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 5

IE efficiency classes

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 6

IEC standard frame

IEC 60072-1

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 7

IEC standard frame

IEC 60072-1

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 8

Main dimensions

A  125mm B  100mm

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 9

Main dimensions

A  125mm B  100mm

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 10

Outer stator diameter

A  125mm

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 11

Shaft height (frame size)

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 12

Stack length

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 13

 Introduction
Operation principles

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 14

Electric motors classification

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 15

Brushed DC vs. Brushless DC

Brushed DC Motor Brushless DC Motor

Advantages Disadvantages Advantages Disadvantages
High maintenance due Complex control (DC to
Easy control (DC Voltage) to mechanical High efficiency
AC)
commutation
Low maintenance Torque ripple
High torque density (the
angle between stator & Electromagnetic noise Without
Operating temperature
rotor is 90deg) electromagnetic noise

Low dynamic response Easy construction Magnets cost

Direct drive
(coppers on rotor)
Fast dynamic response

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 16

Brushed DC Motor

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 17

BLDC motor idea

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 18

BLDC motor idea

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 19

Six-step commutation

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 20

Speed control

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 21

Design possibilities

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 22

Rotor & stator design

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 23

 Analytic Design
Developing analytic design in excel

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 24

Classification of design variables

Fixed Pout , Do
Independent
Adjusted by Lstk
Designer Bav , ar 
Design Variables p
Direct Pout
Tout 
Dependent m
Dependent
Indirect wst , N tc , KgRotor
Dependent

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 25

Electromagnetic design procedure
Fixed Independents Direct Dependents

Electromagnetic Design

 KgAPs  f  Bav , ac, J sw ,...


 OSD  f ( Bav , ac, ar ,...)

Independents Adjusted by Designer  Eff  f  Bav , ac, J sw ,... Indirect Dependents
 :
 Bav  KgAPs
 ar  OSD
 
 Convergence logic 
 J sw  Eff
 :  :

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 26

Direct dependents: output torque

Rated output power

Pout m  2  RPS
Tout 
m RPM
RPS 
60
Rated output torque Rated mechanical speed

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 27

Direct dependents: input power, input current

Rated output power Terminal current (average)

Pout Pin
Pin  It 
d VDC

Rated input power

Desired efficiency Input DC voltage

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 28

Direct dependents: phase & coil current

I ph , peak  I t
I ph
Ic 
2 Np
I ph ,rms  I ph , peak
3

Number of parallel paths

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 29

Output equation: back-EMF

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 30

Output equation: back-EMF

d  d  d e d  d Nm
E ph    e  m 
dt d e dt d e d e 2

max  kw Ntph p

2max Nm
E ph  m 
 2

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 31

 Output equation: back-EMF (slope factor)

max
Slopeline1
ks  1
Slopeline 2

2max Nm
E ph  ks  m 
 2
E ph ,max E ph ,max
ks   max
 2max  / Ts / 2  4max f s

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 32

Output equation: magnetic loading

N m p Bav   DL
Bav  p 
 DL Nm

2max Nm
E ph  ks  m  max  kw Ntph p
 2

E ph  ks kw N tph Bav   DL  2rps

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 33

Output equation: electrical loading

Ns
2  2 N tc  I c , peak 4 N  I
ac  3  tph ph , peak

D D

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 34

Output equation: developed power

Pout  2 E phi ph

4 N tph  i ph
Pout  2  ks kw N tph Bav   DL  2rps  i ph ac 
D

Pout   ks  kw   2  Bav  ac   D 2 L  rps

Pout  G  D 2 L  rps

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 35

Magnetic loading

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 36

Electric loading

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 37

Calculation of main dimensions

Pout L
D L
2
ar 
G  rps p
Aspect ratio
Pole pitch

D p D L 2
p  D 3
p ar  

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 38

Total flux & pole flux & stator tooth flux

total
p 
total  Bav   DL p
Flux under one pole
Total air gap flux

total
 st 
Ns

Stator tooth flux

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 39

Stator slot dimensions

OSD
wst 2
wst1
D bs 2
wst 2 bs1
 wst  bs 0
wsy
wst1 hs 2
hs 0
hs1

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 40

Calculation of width of the stator tooth

wst 2 Width of stator tooth at tip

wst1
 st  Bst  wst1  L  ki
Iron insulation factor
total
 st 
Ns

Width of stator tooth at tail wst 2   wst  wst1

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 41
Calculation of the stator slot dimensions

OSD
y
D wst1
y  tan  / N s  x
bs1 x
hs 0
hs1

 D  wst1 / 2 
bs1  2  tan  / N s     hs 0  hs1   
  2  cos   / N s

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 42

Calculation of the width of stator & rotor yoke

Width of stator yoke

p wsy
 Bsy  wsy  L  ki wry
2
p
 Bry  wry  L  ki
2
Width of rotor yoke

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 43

Calculation of the phase BEMF

Phase back EMF

E ph
 emf 
VDC / 2

Lower than 1: Motor operation

Higher than 1: Generator operation

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 44

Calculation of the number of Ntph and Ntc (initial guess)

Number of effective turns per phase

Total air gap flux

E ph  ks  kw  N tph  tot  2rps

Slope factor

Revolutions per second

Winding factor

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 45

Calculation of the number of Ntph and Ntc (initial guess)

Number of turns per coil

Ns 1
N tph  N tc  
m Np

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 46

Calculation of the slot area
Gross area of coil arm
gAca
Copper area of single conductor
cAsc
Number of parallel strands
N ps  3
Copper area of coil arm

cAca  N tc  cAsc
cAca
gAca  Fill factor
Kf
https://ComProgExpert.com Introductory Course on Design of BLDC Motors 47
Calculation of cAsc (initial guess)

Coil current (RMS)

Ic
cAsc 
J sw
Maximum current density in stator winding

After Calculation of the cAsc we should update it with SWG or AWG table

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 48

 Calculation of the other stator slot dimensions
OSD

wst 2
 2 wst1
 
 s N D
 s
bs 2
  D  wst 2 / 2 
bs 2  2   tan  s / 2     hs 0  hs1  hs 2    bs1
bs 0
   2  cos   s / 2   hs 2 wsy
 b b hs 0
  s1 s 2   hs 2  2 gAca hs1
 2

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 49

Calculation of Magnet Dimensions

dm

p m

m m
m  
 p 2 / p

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 50

Calculation of magnet dimensions

Lstk

dm

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 51

Calculation of magnet dimensions (Rough method)

Lstk
We are looking for desired Bav
By proper adjusting of wm d m

Am  wm  Lstk wm
g m  1
dm Ag  wg  Lstk wy
wm
wy ww   Bm  Am  kl  Bg  Ag

 H .dl  0  H m  d m   H g  g  kr

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 52

Calculation of magnet dimensions (Rough method)

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 53

Calculation of magnet dimensions (Rough method)

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 54

Calculation of magnet dimensions (Rough method)

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 55

Calculation of magnet dimensions (Rough method)
Operating point

 Bm  wm  kl  Bg  wg

 H m  d m   H g  g  kr

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 56

Bg vs. Br
 Bg  wg Bg
 Bm  wm  kl  Bg  wg  Bm  
 wm  kl  m  kl

 H  d   H  g  k  H   H g  g  kr   Bg  g  kr
 m m g r m
dm 0  d m

 Bg   Bg  g  kr 
   M     Br
  m  kl   0  d m 

 m  kl  Br
Bg  Bg   R   m  kr  kl  g
Bm   M H m  Br  m  kl  g  k r dm 
1  R  m  kl  Br  Bg
 Br  dm
M  , R  M
Hc 0
https://ComProgExpert.com Introductory Course on Design of BLDC Motors 57
Calculation of magnet dimensions (MEC method)

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 58

Calculation of magnet dimensions (MEC method)

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 59

Updating process

N tc N tph tot L

 DL
E ph  ks  kw  N tph  tot  2rps  p  Bav 
p
E ph  p ,new Lnew
tot ,new  
ks  kw  N tph ,new  2rps  p ,old Lold

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 60

Calculation of the coil resistance

Resistivity
Mean turn length

Lmt
Rc ,T  N tc  T 
Coil resistance cAsc

T   20 1  T Tamb  Tr  20  

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 61

Mean turn length

Distributed Concentrated

b b   w  wst 2 
Lmt  2  Lstk  4  Lend     s1 s 2   2   st1 
 2   2 

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 62

Calculation of the phase resistance

Number of stator slots

 Ns  1 Number of parallel paths

R ph  Rc    2
 m  Np

Number of phases

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 63

Sensitivity analysis

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 64

 Finite Element Analysis
FEA of the motor and calculation of its electrical parameters and its performance

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 65

Calculation of the magnetic loading

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 66

Calculation of the magnetic loading

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 67

Calculation of the leakage factor

Total flux available in the air gap

kl  1
Total flux generated by magnets

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 68

Calculation of the reluctance factor

Total MMF generated by magnets

kr  1
Total MMF drop over the air gap

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 69

Back EMF simulation

LabelID=Iv_a

LabelID=Ii_a
0A

LCoil1 LCoil2 LCoil18 LCoil10 LCoil9 LCoil11

LabelID=Iv_b

0A LabelID=Ii_b

LCoil6 LCoil7 LCoil8 LCoil15 LCoil16 LCoil17

LabelID=Iv_c

LabelID=Ii_c
0A

LCoil3 LCoil4 LCoil12 LCoil5 LCoil13 LCoil14

0 0

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 70

Back EMF simulation: phase flux linkage

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 71

Back EMF simulation

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 72

Back EMF simulation: phase back-emf

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 73

Back EMF simulation: cogging torque

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 74

Calculation of winding factor and slope factor

Calculated by FEA (BEMF Simulation)

max
max  kw N tph p  kw 
N tph p Calculated by FEA (magnetic loading Simulation)

Bav   DL
p 
Nm

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 75

 Output equation: back-EMF (slope factor)

max
Slopeline1
ks  1
Slopeline 2

2max Nm
E ph  ks  m 
 2
E ph ,max E ph ,max
ks   max
 2max  / Ts / 2  4max f s

Maximum induced phase voltage, Calculated by FEA (BEMF Simulation)

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 76

Calculation of static torque

The angle between rotor and stator field changes from 120 to 60

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 77

 Dynamic simulation
Evaluation of dynamic performance of the motor

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 78

Voltage fed circuit

D2170 D2176 D2182 LabelID=Iv_a LabelID=Ie_a

LabelID=Vi_t LabelID=Vi_a

$Rph
D2174 D2180 D2186
R2214
+
LabelID=V2167
V

V
$Vdc/2 S_2171 S_2177 S_2183 LCOIL_1 LCOIL_2 LCOIL_3 LCOIL_15 LCOIL_14
- LabelID=Iv_b LabelID=Ie_b

LabelID=Vi_b

0 LCOIL_6 LCOIL_7 LCOIL_5 LCOIL_4 LCOIL_8

+ $Rph
LabelID=V2168
$Vdc/2 R2215
- LabelID=Iv_c LabelID=Ie_c

LabelID=Vi_c
LCOIL_9 LCOIL_10 LCOIL_11 LCOIL_12 LCOIL_13

D2172 D2178 D2184

$Rph
R2216
D2175 D2181 D2187
LabelID=Ivca1 LabelID=Ivca2 LabelID=Ivcb1 LabelID=Ivcb2 LabelID=Ivcc1 LabelID=Ivcc2
V

S_2173 S_2179 S_2185

Model Model + LabelID=V2189 + LabelID=V2193 + LabelID=V2196 + LabelID=V2199 + LabelID=V2202 + LabelID=V2205

V
1V 1V 1V 1V 1V 1V
-1V -1V -1V -1V -1V -1V
DiodModel sw_model 100ohm 100ohm 100ohm 100ohm 100ohm 100ohm
R2190 R2194 R2197 R2200 R2203 R2206
0 0 0 0 0 0 0 0 0 0 0 0

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 79

Definition of motion band

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 80

Rotor speed

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 81

Phase currents

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 82

Steady-state phase currents

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 83

Torque plot

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 84

Switching signals

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 85

 Self and mutual inductance
Calculation of the self and mutual inductance

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 86

Voltage equations

d a
va  vN  R phia 
dt
d b
vb  vN  R phib 
dt
d c
vc  vN  R phic 
dt

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 87

Phase flux linkages, inductance matrix, BEMF constants

d a  La  Lb  Lc  Lself
va  vN  R phia 
dt a   La Lab Lac  ia  aM  r   
    L    Lab  Lac  Lba  Lbc  Lca  Lcb  Lm
d
vb  vN  R phib  b  b   ba Lb Lbc  ib    bM  r   
dt  c   Lca Lcb Lc   ic   cM  r   ia  ib  ic  0
d  Ls  Lself  Lm
vc  vN  R phic  c 
dt

dia d aM  r  d aM  r 

va  vN  R phia  Ls  ea   k Ea  r   m
dt dt dt
di d    d   
vb  vN  R phib  Ls b  bM r eb  bM r  k Eb  r   m
dt dt dt
di d    d   
vc  vN  R phic  Ls c  bM r ec  cM r  k Ec  r   m
dt dt dt

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 88

Star connection point voltage

dia
va  vN  R phia  Ls  k Ea  r  m
dt
dib
vb  vN  R phib  Ls  k Eb  r  m
dt
dic
vc  vN  R phic  Ls  k Ec  r  m
dt

va  r , ia   vb  r , ib   vc  r , ic   m   k Ea  r   k Eb  r   k Ec  r  
vN 
3

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 89

Star connection point voltage

v p  va vn  va  1 1  1 1 
  ia  va      v p     ia  va  G1  G2   v p  G1  G2   ia
R1 R2  R1 R2   R1 R2 
v p  vb vn  vb  1 1   1 1 
  ib  vb      v p     ib  vb  G3  G4   v p  G3  G4   ib
R3 R4  R3 R4   R3 R4 
v p  vc vn  vc  1 1   1 1 
  ic  vc      v p     ic  vc  G5  G6   v p  G5  G6   ic
R5 R6  R5 R6   R5 R6 

ia  v p  G1  G2  ib  v p  G3  G4  ic  v p  G5  G6 
va  , vb  , vc 
  G1  G2    G3  G4    G5  G6 

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 90

Star connection point voltage

2 1 1  di
 va  vb  vc  m  k Ea  r   k Eb  r   k Ec  r    R phia  Ls a  k Ea  r  m
3 3 3 3 dt
1 2 1  di
 va  vb  vc  m  k Ea  r   k Eb  r   k Ec  r    R phib  Ls b  k Eb  r  m
3 3 3 3 dt
1 1 2  di
 va  vb  vc  m  k Ea  r   k Eb  r   k Ec  r    R phic  Ls c  k Ec  r  m
3 3 3 3 dt

dia 2  ia  v p  G1  G2   1  ib  v p  G3  G4   1  ic  v p  G5  G6    2 1 1 
Ls   R phia     m   k Ea  r   k Eb  r   k Ec  r  
dt 3  G1  G2  3  G4  G4  3  G5  G6   3 3 3 
dib 1  ia  v p  G1  G2   2  ib  v p  G3  G4   1  ic  v p  G5  G6    1 2 1 
Ls   R phib     m   k Ea  r   k Eb  r   k Ec  r  
dt 3  G1  G2  3  G4  G4  3  G5  G6   3 3 3 
dic 1  ia  v p  G1  G2   1  ib  v p  G3  G4   2  ic  v p  G5  G6    1 1 2 
Ls   R phic     m   k Ea  r   k Eb  r   k Ec  r  
dt 3  G1  G2  3  G4  G4  3  G5  G6   3 3 3 

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 91

Star connection point voltage

 2 1 1 
 dia     R ph 
 dt   3  G1  G2  3  G3  G4  3  G5  G6   i 
    a
di 1 2 1
Ls   b      R ph  ib  
 dt   3  G1  G2  3  G3  G4  3  G5  G6   
     ic 
 dic   1 1 2
 dt     R ph 
 3  G1  G2  3  G3  G4  3  G5  G6  
 2  G1  G2  1  G3  G4  1  G5  G6  
        2 1 1 
          
 3 G1 G 2 3 G 3 G 4 3 G5 G6  3 3 3   k   
 1 G  G  2 G  G  1 G  G     Ea r
1 2 1   
v p    1 2
  3 4
  5 6
  m      k Eb  r  
 3  G1  G2  3  G3  G4  3  G5  G6    3 3 3 
     k Ec  r  
          1 1 2
1
  G1 G2 1
 
G3 G4 2
 
G5 G6   
 3 G  G  3 G  G  3 G  G    3 3 3 
 1 2 3 4 5 6 

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 92

Mechanical equations

d r
m 
dt

d m
Te  r   Tl  Dm  J m
dt

Tem  ea ia  ebib  ecic  k Eamia  k Ebmib  k Ecmic

Te  k Ea ia  k Ebib  k Ecic

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 93

 State space equations

 dia    2 R 1 1 2k Ea  r   k Eb  r   k Ec  r    vp  2  G  G2  1  G3  G4  1  G5  G6   
  ph 0       1      
 dt  3  G1  G2  Ls Ls 3  G3  G4  Ls 3  G5  G6  Ls 3Ls  Ls  3  G  G  3  G  G  3  G  G  
   1 2 3 4 5 6
  
 dib   1 2 R 1 k Ea  r   2k Eb  r   k Ec  r    ia   v p  1  G1  G2  2  G3  G4  1  G5  G6   
 dt     ph 0            
   3  G1  G2  Ls 3  G3  G4  Ls Ls 3  G5  G6  Ls 3Ls   ib   Ls  3  G  G  3  G  G  3  G  G  
 1 2 3 4 5 6
 c 
di
R

k Ea  r   k Eb  r   2k Ec  r    ic    v
 dt  
1 1

2
 ph  1  G  G2  1  G3  G4  2  G5  G6   
0    p     1      
 d   3  G1  G2  Ls 3  G3  G4  Ls 3  G5  G6  Ls Ls 3Ls   r          
 r       Ls  3 G1 G2 3 G3 G4 3 G5 G6 
 dt   0 0 0 0 1  m   0

   
 d m  k Ea  r  k Eb  r  k Ec  r  D  T 
   0 
  l 
 dt   Jm Jm Jm Jm  Jm
 

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 94

 Demagnetization study
Demagnetization study under worst case current and temperature

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 95

Demagnetization study (HB Curve of Magnet)

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 96

Demagnetization study (HB Curve of Magnet)

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 97

Demagnetization caused by overload

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 98

Demagnetization caused by temperature increase

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 99

 Motor efficiency
Calculation of the motor losses and efficiency

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 100

Calculation of the motor efficiency

Copper losses
The difference between the total
losses and the sum of stator and rotor
Iron losses
resistive losses, stator and rotor iron
losses, and mechanical losses
Total losses Magnet losses IEC 60034-2-1

Additional losses
bearing friction losses

Mechanical losses windage losses of rotating rotor

ventilator losses

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 101

Calculation of the motor efficiency

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 102

Copper losses

AC resistance
RAC  k R  RDC
Phase current
PCu  mRAC I 2
ph
AC resistance factor
Number of phases

k R  k R ( f ,  , Br ,...) pcu (t )  R ph  (i  i  i ) 2
a
2
b
2
c

• Frequency
• Load angle Pcu  pcu (t )
• Rotor magnetic field
avg

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 103

Iron losses

Hysteresis losses

Total losses Eddy current losses

Excess losses

pFe  Cdc kh fB  kc f B  ke f B
2 2 2 1.5 1.5

Cdc  1  kdc Bdc2 kdc ,default  0.65

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 104
Iron losses

Hysteresis losses

Total losses Eddy current losses

Excess losses

pHyst  Cdc kh fB 2

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 105

Iron losses

Hysteresis losses

Total losses Eddy current losses

Excess losses

conductivity
pEddy  kc f B 2 2 Thickness of the lamination

 2 d 2
kc 
6
https://ComProgExpert.com Introductory Course on Design of BLDC Motors 106
Iron losses

Hysteresis losses

Total losses Eddy current losses

Excess losses
Excess or anomalous loss is due to eddy
currents generated by the displacement of the
magnetic domain walls

pExcess  ke f B 1.5 1.5

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 107

Calculation of the mechanical losses

bearing friction losses

Mechanical losses windage losses of rotating rotor

ventilator losses

Prot
 prot 
Pout

%1   prot  %4

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 108

Some of the references

I. J. Pyrhonen, T. Jokinen, and V. Hrabovcova, Design of rotating electrical machines. John Wiley & Sons,
2013.
II. D. C. Hanselman, Brushless permanent magnet motor design.
III. R.K. Agarwal, Principles Of Electrical Machine Design.
IV. A. K Sawhney, A course in electrical machine design.

https://ComProgExpert.com Introductory Course on Design of BLDC Motors 109