Buy Custom Designed BLDC Motors to Meet Your Specific Application

Brushless DC motors are synchronous electric motors that get power from a direct current. As the name implies, a BLDC motor does not have any carbon brushes. Instead, it works via electronic commutation with a controller. A brushless DC motor operates through a six-step electronic commutation system. Electromagnets are placed in the motor instead of carbon brushes, and they do not move together with an armature as encased permanent magnets rotate to generate torque. And because a BLDC motor is synchronous, both the magnetic field and stator generate similar frequency to prevent slippage, which tends to occur in most induction motors.

A six-step commutation is a type of electronic commutation that is cost effective due to the simple and inexpensive drive devices and feedback. Only two out of three BLDC motor windings are used at a time. The steps are equal to 60 electrical degrees. Hence, six steps would result in a complete 360-degree rotation. A full loop should control the current because of the single current path. A six-step commutation is ideal for applications that require high commutation frequencies and speed. Six-step BLDC motors typically have lower torque efficiency compared to a sine-wave commuted motor.

When shopping for custom brushless DC motors, be sure to look for a company with years of experience in manufacturing, engineering, and designing AC and DC motors for a wide range of commercial and industrial applications. Some of the best sources for custom designed BLDC motors have their team of engineers who can understand your needs and design the right product to suit your requirements. Buy BLDC motors from a company with its manufacturing facility, so they can effectively control production and ensure the highest standard of quality control.

Brushless DC motors are usually manufactured with an electronic controller, which replaces a mechanical commutation system. Either a back electromotive force (EMF) or the Hall Effect sensor is used to determine the rotor's position. It is important to determine and understand the rotor's position to ensure the proper operation of a brushless DC motor. For more precise applications, custom BLDC motors can have optical encoders, which can help you determine both speed and direction. An optical encoder can be used with third index signals to let you know the pulse per revolution.

Advancements in design and material have helped reduce the price of brushless DC motors since they were introduced. This is why BLDC motors have become increasingly common in a wide variety of applications, like medical, automotive, military, aerospace, medical, and factory automation equipment. The greatest advantage of a BLDC motor is the absence of brushes, which typically must be replaced when they wear out or get damaged, resulting in more costs for your business. Moreover, brushless DC motors are lighter and smaller, so they are ideal for applications where space and weight are important considerations.

This article is written by Jack Wang who is associated with GEMS Motor. Jack got his Bachelor's degree in Mechanical Engineering and Master's degree in Electrical Engineering, specialized in electric motor design.