Custom Electric Brushless DC Motor Manufacturers

How is the electronic commutation of electric brushless DC motors achieved? ​
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In the field of modern industry and intelligent equipment, Electric Brushless DC Motor has gradually become the core choice of drive systems with its significant advantages such as high efficiency, energy saving and long life. As a professional gearbox, reducer and motor manufacturer, Hengbai Reducer occupies an important position in the market with its outstanding technical strength and strict quality control. It has obtained many honorary certificates and credit ratings, and has obtained quality management systems, professional technical personnel, scientific management systems, strong economic strength, advanced processing equipment and perfect after-sales services, making its products not only popular in various provinces and cities in China. In the technical research and development and production of Brushless DC Motors, we strictly implement the procedures of raw material supplier screening and review, incoming material inspection, and incoming material comparison. Through first-class production process design and program control, we ensure that each batch of products is stable and traceable, and realize efficient production control. Behind its excellent and stable product quality, the electronic commutation technology of BLDC Motors plays a key role. ​
The biggest difference between electric brushless DC motors and traditional brushed DC motors is that they abandon mechanical commutators and brushes and adopt electronic commutation systems instead. Traditional brushed DC motors rely on mechanical contact between brushes and commutators to change the direction of current and achieve continuous rotation of the motor, but this method has problems such as brush wear, spark generation, high maintenance cost, and short life. The electronic commutation system of electric brushless DC motors uses electronic circuits and sensors to accurately control the direction and size of the current in the motor windings, thereby achieving smooth operation and efficient control of the motor. ​
Electric brushless DC motors are mainly composed of four parts: stator, rotor, position sensor, and electronic commutation circuit. There are multiple windings installed on the stator, generally three-phase windings, which are arranged according to a specific rule and generate a rotating magnetic field when current passes through. The rotor is usually made of permanent magnetic material, and generates torque under the action of the stator's rotating magnetic field to achieve the rotation of the motor. The position sensor is one of the key components of the electronic commutation system. It can detect the position information of the rotor in real time and feed the information back to the electronic commutation circuit. Hengbai Reducer uses high-precision position sensors when producing brushless DC motors to ensure that the rotor position can be accurately captured, providing an accurate basis for electronic commutation. Common position sensors include Hall effect sensors, photoelectric sensors, and magnetoresistive sensors. Different types of sensors have their own characteristics in terms of performance, accuracy, cost, and applicable scenarios. Hall effect sensors use the Hall effect. When a magnetic field acts on the sensor, a Hall voltage is generated. The rotor position is determined by detecting the change in the Hall voltage. Photoelectric sensors determine the rotor position by emitting and receiving light according to the position change of the light shield on the rotor. Magnetoresistive sensors are based on the magnetoresistive effect and use the property that the resistance of magnetic materials changes with the magnetic field to detect the rotor position. ​
The electronic commutation circuit is the core part of realizing the electronic commutation of electric brushless DC motors. It receives the rotor position signal from the position sensor, and according to the preset control strategy, applies a suitable current to the stator winding in a certain order and time interval, thereby generating a rotating magnetic field and driving the rotor to rotate. The electronic commutation circuit is generally composed of power electronic devices, drive circuits, and control circuits. Power electronic devices, such as insulated gate bipolar transistors or metal-oxide semiconductor field-effect transistors, are responsible for controlling and switching the current in the stator windings. Hengbai Reducer selects high-quality power electronic devices and combines advanced processing equipment in the design and production of electronic commutation circuits to ensure the stability and reliability of the circuit. The function of the drive circuit is to amplify the small signal output by the control circuit to drive the power electronic devices to turn on and off. The control circuit is the brain of the entire electronic commutation system. It calculates the appropriate commutation time and current size according to the signal of the position sensor and the external control instruction, and sends the corresponding control signal to the drive circuit. ​
The specific implementation process of electronic commutation of electric brushless DC motors is as follows: Taking the common three-phase brushless DC motor as an example, when the motor starts, the position sensor detects the initial position of the rotor and transmits the signal to the control circuit. The control circuit sends a control signal to the drive circuit according to the rotor position. After the drive circuit amplifies the signal, it controls the power electronic devices to turn on two phases in the stator winding and generate a magnetic field. For example, the A-phase and B-phase windings are turned on first, and the current passes through these two phase windings to generate a magnetic field, which interacts with the permanent magnet of the rotor to generate torque and drive the rotor to rotate. As the rotor rotates, the position sensor continuously detects the rotor position and feeds the new position signal back to the control circuit. When the rotor rotates to a certain angle, the control circuit determines that commutation is required based on the position signal, so a new control signal is sent to the drive circuit to change the conduction state of the power electronic device, so that the A-phase and C-phase windings are turned on, or the B-phase and C-phase windings are turned on. By continuously detecting the rotor position and changing the power-on sequence of the stator windings in a timely manner, the stator magnetic field continues to rotate and interacts with the rotor permanent magnet to achieve continuous rotation of the motor. ​
In this process, precise control of the electronic commutation system is crucial. If the commutation moment is inaccurate, it will cause motor torque fluctuations, reduced efficiency, and even stalling. Hengbai Reducer, with its professional technical personnel and scientific management system, conducts in-depth research and optimization of the electronic commutation system. In terms of program control, the commutation moment is calculated through precise algorithms to ensure smooth operation of the motor. At the same time, the quality of each batch of products is strictly monitored in accordance with the specifications of the supplier. From the selection of raw materials to the control of the production process, every link is refined to ensure the stability and reliability of the electronic commutation system. ​
The electronic commutation technology of electric brushless DC motors also has many advantages. Since there is no mechanical commutator and brush, friction and wear are reduced, the noise during motor operation is reduced, and the service life and reliability of the motor are improved. The electronic commutation system can achieve precise speed control and torque control to meet the needs of different application scenarios. Brushless DC motor products are widely used in industrial automation equipment, smart homes, new energy vehicles and other fields, thanks to these advantages of electronic commutation technology. In industrial automation equipment, brushless DC motors can accurately control the speed and torque according to the requirements of the production process, improve production efficiency and product quality; in the field of smart homes, its low noise and long life provide users with a more comfortable experience; in new energy vehicles, the high efficiency and energy saving characteristics of brushless DC motors help to extend the vehicle's cruising range. ​
With the continuous development of science and technology, the electronic commutation technology of electric brushless DC motors is also continuously innovating. New position sensors continue to emerge, improving the accuracy and reliability of position detection; the application of more advanced power electronics and control algorithms further improves the performance and efficiency of motors. We will continue to increase investment in research and development, keep up with industry development trends, and continuously optimize the electronic commutation technology of brushless DC motors. With excellent and stable product quality, we will provide global customers with better gearboxes, reducers, motor products and solutions, and promote the application and development of electric brushless DC motors in more fields.