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What is a Brushless DC Motor with Integrated Commutation Electronics?

November 19, 2012 0 Comments

A brushless DC motor with integrated commutation electronics will operate when nothing more than appropriate DC voltage is applied. Unlike conventional brushless DC (BLDC) motors that require connection to a separate driver/amplifier containing commutation logic those critical capabilities are built into the motor itself, thereby, making it much easier to wire and install in equipment.

Conventional brushless dc motor BLDC  and control schematic

Conventional brushless dc motor and control schematic

A traditional brushed DC motor (PMDC) commutates itself by using a mechanical commutator. However, the commutator and the carbon brushes that make contact with it wear over time and also create brush dust in the motor, both of which are limiting factors in the motor’s operating lifetime expectation. The brushless DC motor eliminates that lifetime limiting wear factor by employing solid state electronic commutation. While PMDC motors can be driving directly with simple two-wire application of DC power (like from a battery). However, to turn the shaft of a BLDC motor it is necessary to precisely switch the current to the stator windings at the appropriate intervals in relation to the position of the rotating magnetic field. As the schematic above illustrates, that has traditionally required a control separate from the motor and connected with a complex, expensive multiwire cable.

However, Dunkermotor has been able to design brushless DC motors that incorporate those functions into a single compact package.The motor does not have any parts subject to mechanical wear other than the ball bearings and, therefore, are excellent for use in continuous duty applications. The power connections are simple and digital inputs are available to change rotation of the motor.

In essence, the Dunkermotor KI brushless DC motors offer the performance and reliability of brushless technology with simple, two-wire control as in a brushed PMDC motor. In many medical and industrial OEM pump applications the Dunkermotor KI BLDC motors can be a drop-in replacement for the brushed motor without having to change anything else in the control scheme. Varying the DC voltage to the motor varies the speed and, in most cases, the life of the motor is easily increased by a factor of 5 or more. Dunkermotor 2-wire KI motors are for single-direction applications and other KI motors have the ability to reverse direction, stop and hold via more IO. In addition, theKI series brushless motors can be combined with planetary or worm gearboxes in a wide range of reductions to meet most applications.

In the past, adoption of brushless DC motors in OEM applications was hindered by their requiring a separate control that cost almost as much as the motor and the costly cables and connectors to mate them — all of which was further complicated by the additional labor required for installation and start-up. Today’s brushless DC motors with integrated commutation electronics have eliminated those obstacles and prove their value in new applications everyday. Speaking of value, the integral package far outshines the added up cost of the separate components.

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About the Author:

John Morehead is an experienced marketing, sales and business development leader. He’s passionate about motion control and advanced motor technology and shares that enthusiastically with those he encounters and many more through his myriad marketing initiatives. This blog is one more tool to be able to spread the word about news, information and insights on the motion control, electric motors, drives and automation fields. Your comments or questions on posts are welcome.

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