Mechatronics and Automation

Ex-3 DC Motor Design

DC Motor Design
Brushed DC VS Brushless DC

Features Brushed DC Motor Brushless DC Motor

Commutation Mechanical commutator Electronic commutation based
on rotor position information
Commutation Tool brushes are used for Electronic circuit and sensors
commutation are used for commutation
Efficiency High efficiency Moderate efficiency
Maintenance None Periodic
Thermal performance Better Moderate
Output Power High Moderate/Low
Speed/Torque Characteristics Flat Moderately flat
Dynamic Response Fast Slow
Speed Range High Low
Electric Noise Low High
Lifetime Long Short
Common Specifications

Nominal voltage: This is at the same time the voltage at which the other specs were measured, and the
suggested voltage at which the performances are the best, most of the time. You can consider using the
motor with the nominal voltage without any problem, or a at value above it. Be advised that a too high
voltage will result in damaging the coils.

No-load speed: Exactly as it is named, this is the rotational speed of the motor’s output when no load is
applied to it, i.e. when nothing is linked to the output. This is the maximal speed the motor can reach at a
given voltage.
No-load current: Current consumed by the motor while continuously rotating at no-load speed.

Stall torque: It is the maximal torque that can be applied to the rotor until it stops spinning.

Starting (or stall) current: Current consumed by the motor at stall torque condition. This current is
observed as a peak when a rotor stars rotating
Common Specifications

Rated (or continuous) speed, torque and current: These three values are linked together and define a
functioning point of your speed-torque curve. This is a point at which the conditions are the best to
ensure maximum efficiency.

Maximum continuous current and torque: (Sometimes called nominal current and torque.) A point of the
speed-torque curve which is at the limit between continuous and intermittent ranges. At this point the
amount of current still ensures that the winding is not overheating. Above these values, the motor is likely to
overheat quickly. Under them, the amount of current allows the rotor to dissipate the heat.

Peak torque: For most retailers, peak torque is the maximum possible torque a motor can provide in
intermittent use, i.e. for a short time, and without damaging itself and reducing its lifespan.
Brushed DC Motor specification

The datasheet of RF-370CHV brushed DC motor

on the Mechatronic Actuators board.
BLDC Motor Specification
Torque and Speed curve

𝑉−𝑉𝑏
T=kt×i i= Vb= Kb×
𝑅
Where Where Where
Kt = Torque constant V- Voltage of the DC motor Kb- Back emf
i-Current R-Armature resistance -Angular velocity (Speed)
Mechanical information about the motor
BLDC Motor
Common design criteria
Cost
Cost will often be the principal driver in a design. The final cost of a motor will depend on
a large number of variables, including volume of production and the location of the manufacturer.
However, in general, brushed DC motors have an advantage as they have fewer components.
The lack of hall-effect sensors and the simpler coil wiring means that if cost is the principal design
limitation, then brushless DC motors will likely not be applicable.

Efficiency
The efficiency of a motor is the ratio of the electrical power supplied to the motor (1 watt = 1 volt *
1 amp) to the mechanical power supplied by the motor (1 watt = 1 Nm * 1 rad/s). This relationship
is likely non-linear, however, the efficiency of a motor at a given speed and torque can usually be
inferred from the torque-speed plot like that shown in figure. Since this plot shows the current
draw and the test is at a constant voltage, all the information required to calculate the motor
efficiency is available. However, if one is looking for a general rule, brushless DC motors do not
have to overcome the friction caused by the brushes and as such are usually slightly more
efficient.
Common design criteria

Easy of Use
This is harder to quantify based on technical documentation, however, the overriding factor in ease of use
for DC motors is the complexity of the motor control circuitry. Due to the complex excitation signals required
to drive a brushless DC motor, the brushed motor will almost always be easier to use. In some cases, this gap
can be narrowed through the use of an off-the-shelf brushless DC motor driver; however, this will have an
effect on the overall cost of the solution.

Lifespan
The lifespan of the motor will often be given in the datasheet either in term of hours of operation or number
of rotations. Generally, because brushes are subject to friction wear, the lifespan of a brushed DC motor will
almost always be less than that of a comparable brushless DC motor.

Power-to-Weight Ratio
This is the other factor where the complexity of the brushless DC motor is offset. Because there is more
flexibility in the design of the rotor/stator combination for the brushless DC motor, they generally achieve
greater power for a similar weight and size than the brushed DC motor.
Thank you