Brushless DC Motor Primer
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Brushless DC Motor Primer By Muhammad Mubeen [email protected] Last Revision: July, 2012 1 Foreword This primer on brushless DC motors has been written for the benefit of senior management executives of OEM companies in whose products, the electric motor is a major cost and feature component. The focus of this primer is permanent magnet brushless DC motors (BLDC), sometimes referred to as ECM (Electronically Commutated Motors). The material has been written from the stand point of top management. It has technical depth but is really meant to be used as a tool for senior management to get a quick and broad overview of the technology and the underlying pros and cons. It is my intent that the material presented will quickly make the reader well versed with the technology and give him or her a deep understanding of major impact of BLDC technology on their own competitiveness. Most important of all, the material is designed to point out ways in which the technology can be harnessed to advantage. Conversely, the material also points out the perils of ignoring these profound changes in the motor technology landscape. Muhammad Mubeen Radford, VA July, 2012 2 Overview of the Electric Motor Business in North America According to some estimates, the overall consumption of electric motors of all types in North America will be $18 Billion by 2007 up from $14 Billion in 2002 with an annual growth rate of 5%. The breakdown of this overall picture of consumption by motor technology looks as follows for 20071. 2007 Electric Motor Consumption in North America Total $18B All Other, $1.4, 8% AC Induction, $5.0, 28% BLDC, $4.1, 23% Brush DC, $7.4, 41% The consumption of electric motors is heavily influenced by the automotive industry and consumer applications. A majority of electric motors used are brush type DC motor, followed by AC induction motors and brushless DC (BLDC) motors. All other category of motors include, AC/DC motors called “Universal” motors used in appliances and stepper motors, used in low end position control applications. With this broad picture presented above, it is now relevant to look at the details, differences and applications of the various motor technologies. 1 Source: MTT NA Market Model. www.motioninfo.com 3 Motor Technology General Principle of All Electric Motors: All electric motors have a common principle in that they function as converters of electrical energy to magnetism to mechanical rotating motion. The underlying way in which this conversion takes place is fundamentally the same in all types of electric motors. The differences lie in the details of the manner in which magnetism (magnetic field) is generated to get rotational force or “torque”. Underlying Basics of All Types of Electric Motors Electrical Magnetic Mechanical Energy Energy Energy (rotating force: torque) From fundamentals, we know that bar magnets have invisible lines of force around them and flow from the North Pole to the South Pole. 4 The concept of magnetic attraction and repulsion When magnets are brought close to each other, they generate a force of attraction (with adjacent unlike poles) or repulsion (with adjacent like poles). The generation of the mechanical force is fundamental to the way in which all electric motors operate. It can be intuitively seen that to get greater electromagnetic force, the following notions are true: - Larger magnet area will result in a larger electromagnetic force. - More powerful magnets will result in a larger electromagnetic force - If the magnets are brought closer together (reduced air gap), the electromagnetic force can be increased. As an extension to the fundamental notion that like poles attract and unlike poles repel, we can look at an “electromagnet” generated by the flow of current through an electrical conductor. So, in place of a permanent magnet pole, we now have a electromagnetic pole. In the following picture, imagine the current is flowing in a conductor through the paper. Magnetic lines of force are generated around the conductor as shown. The Concept of a magnetic field generated by a flow of current in a wire. 5 The Concept of an Electromagnet….. current flowing through “N” number of turns of wire N S So, we have a conversion of electrical energy to magnetic energy… the force of attraction or repulsion between magnetic poles. Now, if we introduce the concept of a rotor (moving magnetic poles) and a stator (stationary magnetic poles) we can see how rotating movement may be generated. If there are just two poles one north and one south, there will be attraction between the two and they will line up. The force with which they will line up will depend on the current flowing through and the number of turns if they are electromagnets or the strength and the size of the magnets, if they are permanent magnets. If one of these poles is somehow moved to an adjacent spot, the other magnet will follow. If it is moved again, its mate will follow again and a rotating motion will be achieved by this “rotating field”. The rotating force will depend on the strength of the magnets, the air gap and the length of the fulcrum – the torque arm. The Concept of Rotating Field 6 Before getting into the differences in the various types of motors based on how the rotating field is generated, we now introduce the concept of torque, which is a very important concept in the study of electric motors and common to all types of motors. After all, the purpose of an electric motor (any type of electric motor) is to generate torque (or rotating force). By definition, torque is the rotating force x the distance at which the force is being applied. So, intuitively we can see that in order to get greater torque, we need to either increase the force (stronger magnets, more current) and increase the distance at which this force is being applied (physically larger magnets) The Concept of Torque T (lb-in) = F (lbs) x R (in) F R T (lb-inches) = Force (lbs) x Distance (inches) Or in the metric system: T (Newton-Meters) = Force (Newtons) x Distance (meters) 7 The next important concept in the study of electric motors is the concept of “Power”. In a rotating device such as an electric motor, Power has two elements: the rotating force (torque) and the speed at which this power is being applied. The product of torque and speed is the power in watts. This is the same concept electrically, where the power is the product of Volts x Current. The Concept of Power Power = Speed x Torque Watts = Speed (Radians/sec) x Torque (Newton-meters) 746 Watts = 1 Horse Power Electrical Power = Volts x Current (amps) = Watts To finish the discussion, we now introduce the concept of efficiency. Efficiency is not only important from the stand point of how much electricity is consumed but also, everything else being equal, a higher efficiency motor will generally require lesser amount of materials to produce a given amount of power. This of course has implications on the overall cost of the motor. There are nuances relative to real power versus imaginary (not in phase) power, but the following box illustrates the general concept of efficiency. The Concept of Efficiency Power output Po Power input Pi Losses Po-Pi Efficiency Power Output (Po)_ % = Speed x Torque Power Input (Pi) Volts x Amps 8 One other important concept in the study of motors, before we get into the different types of electric motors is the concept of the speed torque curve or speed-torque chart. Any type of electric motor produces rotating force (torque) at a given speed. Intuitively, as the torque is increased (for example when the motor is loaded down such as with a brake), the speed will decrease. The overall power output remains the same less of course any loss in efficiency, but the product of the speed and torque (the power) remains the same. A useful concept to describe the performance of a motor is the speed-torque curve. This is a fundamental way in which the performance of any motor is characterized. Here is an example of a speed torque curve. The concept of a speed-torque curve… Speed is commonly called out in RPM (or Radians per second) and the torque in lb-inches (or Newton-meters). As the voltage is increased, the speed-torque envelope moves upwards. 9 CHAPTER 2: DIFFERENT TYPES OF ELECTRIC MOTORS Induction AC Motors Earlier we introduced the concept that all electric motors shared the common underlying principle which converts electrical energy to magnetic energy to rotating mechanical energy. We also introduced the concept of a rotor and stator and the rotating field which results in rotational movement. The different types of motors result from the various clever ways in which the rotor and stators are constructed and the manner in which the rotating field (which is essential to rotating movement) is generated. In an induction motor, the rotor is the inner part and the stator is the external part. The AC electrical current is fed into the stator. As the sine wave of the AC electrical current goes up and down, it creates a rotating field. The rotor consists of a series of bars which are welded together at either end. The current is “induced” in the rotor from the electrical field in the stator. This current circulates in the bars of the rotor and the magnetic field generated by it reacts with the stators field. As the magnetic field in the stator rotates, the rotor follows and rotating force (torque) is generated.