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Today’s fast-paced prototype-to-production focus tends to dissuade design engineers from developing a custom controller using discrete parts. The initial factors that help shape the overall design of an embedded motor controller are: When designing an embedded motor controller, there are several design considerations. A power output stage that drives the motorĪn analog-to-digital function converts the shaft rotational sensor signals into the digital domain for processing by the microcontroller.Pulse Width Modulation (PWM) circuitry that provides the switching signals.A microcontroller that runs the motor control algorithm.These three distinct circuit functions are achieved through:
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The Architecture of a BLDC Motor ControllerĪs discussed in the section above, there are three distinct circuit functions required for a brushless motor controller. Field-oriented control (FOC) refers to using the induced field voltage.Ī sensorless method helps improve overall motor reliability as well as reducing the bill of materials (BOM) cost.
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Manufacturers construct brushless DC motors using fixed permanent magnets on the rotor drive shaft and a series of field windings (typically three) on the inside of the motor casing.
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Audible noise from brushed motors is also now considered undesirable, particularly for portable battery-powered appliances such as vacuum cleaners and personal power tools, including jigsaws and drills/drivers. In today’s complex and sophisticated control applications, brushed motors also create too much electrical noise, which means designers need to employ substantial electromagnetic immunity mitigation techniques.
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More reliable and requiring significantly less maintenance than their brushed DC motor counterparts, brushless DC motors have also benefited from a broader industry understanding of how to control them using simple microcontroller algorithms. Brushless Motors Gain Tractionīrushless DC (BLDC) motors have become the default choice of motor for a wide range of battery and line-powered equipment and appliances. This post first appeared on the Mouser Electronics website, by Robert Huntley, a frequent contributor to Mouser Electronics’ blog. Solving Brushless DC Controller Design Challenges
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