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Understanding Brushless Motors in One Text: From Structural Design to Application Scenarios

ReleaseTime: 2025-04-30

Brushless motor, also known as electronic commutation motor or synchronous DC motor, is a type of synchronous motor powered by DC electricity. It inputs DC power and converts it into three-phase AC power with the help of an inverter, belonging to permanent magnet synchronous motors with position feedback. In the motor family, brushless motors have gradually become the "new favorite" in many fields due to their unique advantages. ​

From the perspective of structural design, brushless motors are mainly composed of three parts. The rotor part is made of permanent magnet materials, such as common rare earth alloy magnets neodymium, samarium cobalt, and neodymium iron boron. According to different applications, the number of poles varies between 2 and 8, with the north pole (N) and south pole (S) arranged alternately. Common forms of magnetic pole arrangement include placing magnets on the outer circumference of the rotor, embedding rectangular permanent magnets into the rotor core, and inserting magnets into the rotor core. The structure of the stator is similar to that of an induction motor, consisting of stacked steel laminations with axial slots for winding coil windings. Most brushless motors are equipped with three stator windings connected in a star or "Y" shape (without a neutral point), and according to the coil interconnection method, the stator windings can be further divided into trapezoidal and sinusoidal motors. The driving current and back electromotive force of trapezoidal motors are trapezoidal, while sinusoidal motors are sinusoidal. Position sensors (often Hall sensors) also play a key role in brushless motors. Due to the abandonment of electric brushes in brushless motors, commutation relies on electronic control. To ensure smooth rotation of the motor, it is necessary to sequentially energize the stator winding, which requires knowledge of the rotor position. Hall sensors can detect the rotor position and convert it into electrical signals. Most brushless motors have three built-in Hall sensors to achieve this goal. ​

In terms of application scenarios, the presence of brushless motors can be seen everywhere. In the field of model aircraft, its lightweight and high power density characteristics can help aircraft fly flexibly. On industrial production lines, brushless motors have become the driving force for many devices due to their high torque, high reliability, and ability to operate stably for a long time. In smart home devices, the low noise and energy-saving advantages of brushless motors are highlighted. For example, household appliances such as air conditioners and refrigerators use brushless motors as drivers, which not only improve performance, reduce energy consumption, but also reduce operating noise and optimize user experience. In the automotive industry, with the rise of electric and hybrid vehicles, brushless motors provide efficient power to vehicles and have increasingly broad application prospects. In the emerging field of robotics, the fast response and precise control characteristics of brushless motors make robot movements more flexible and task execution more efficient. Brushless motors, with their exquisite structural design, have achieved many breakthroughs in performance, demonstrating strong applicability in a variety of scenarios and continuously promoting technological innovation and development in various industries.

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