BLDC - ABSTRACT This paper presents the design of a hp...

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ABSTRACT: This paper presents the design of a ¾hp brushless DC motor used for in home applications. The designed motor is a three-phase, four-pole, twelve-slot machine. The paper covers all aspects of the design beginning with the type of motor and finishing with the production and shipping of the motor. It also includes the design options for control circuits, number of turns and types of winding. The final product meets most of the goals set by the IEEE project guidelines.
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50, 21, 17, 14 STRONG, COX, CAREY, BELKNAP 2 TABLE OF CONTENTS ABSTRACT: 1 TABLE OF CONTENTS 2 TABLE OF FIGURES 3 INTRODUCTION 4 I. B ACKGROUND 5 II. M OTOR TYPES 5 III. C ONTROL S YSTEMS 8 SOLUTION 18 I. O VERALL D ESIGN 18 II. C ONTROL S YSTEM C HOSEN 35 III. E NCLOSURE & HARDWARE C HOSEN 35 IMPLEMENTATION 38 I. M ANUFACTURING 38 II. M OTOR C ONSTRUCTION : 41 III. T ESTING 45 IV. P ACKAGING 46 RESULTS 48 I. D ESIGN REQUIREMENTS 48 II. A DDITIONAL HARDWARE SPECIFICATIONS 51 SUMMARY 54 APPENDIX A PROJECT REQUIREMENTS 55 REFERENCES 58
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50, 21, 17, 14 STRONG, COX, CAREY, BELKNAP 3 TABLE OF FIGURES Figure 1: Basic diagram of 4-pole, 3-phase, 12-slot motor [2: 1-5] 7 Figure 2: Winding inputs from different VFDs [3: 1359] 10 Figure 3: Control system block diagram for square wave BLDC controller [2: 2-42] 11 Figure 4: Block diagram of control setup. 11 Figure 5: Circuit diagram of wye-connected motor [2: 10-3] 12 Figure 6: Circuit diagram of delta-connected motor [2: 10-3] 13 Figure 7: Three phase AC signal [4] 14 Figure 8: Two types of optical encoder disks [2: 1-21] 16 Figure 9: Effect of poles, teeth, and phases on motor design [6: 5.15] 22 Figure 10: Simple view of rotor and permanent magnets [2: 3-7] 23 Figure 11: NEMA type 48 frame dimensions 25 Figure 12: Motor casing dimensions 26 Figure 13: Motor configuration and values (in mm) 27 Figure 14: Winding setup for one of three phases 28 Figure 15: Coil setup for BLDC motor 29 Figure 16: Flux distribution due to magnets alone (open-circuit condition) [2: 12-22] 32 Figure 17: Lamination template 33 Figure 18: Internal view of bearing components 36 Figure 19: External views of bearings 36 Figure 20: Static shielding bags [12] 46 Figure 21: Foam-enforced boxes [12] 47
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50, 21, 17, 14 STRONG, COX, CAREY, BELKNAP 4 INTRODUCTION Every day, electric motors become increasingly necessary in our advancing society. While only fifty years ago the average household possessed very few motors, the average home today could contain over a hundred. Motors today power everything from dishwashers and vacuum cleaners to computers and video game systems. Motors provide the driving force for so many things, and with such an enormous demand, the incentive to design and sell motors becomes unavoidable. This project aims to provide an inexpensive and economical solution to one of the most common residential motor applications, the ¾hp motor. The project also aims to decrease overall power consumption by providing an energy-efficient replacement for current ¾hp electric motors.
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