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Design Aspects of BLDC Motor and MagNet Software
Presentation · August 2020

DOI: 10.13140/RG.2.2.17371.59689
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Carunaiselvane Carounagarane
Indian Institute of Technology Roorkee
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DESIGN ASPECTS OF BLDC MOTOR AND
MAGNET SOFTWARE
Dr. CARUNAISELVANE.C
Indian Institute of Technology Roorkee
carunaiselvane@gmail.com
Contents
1. Introduction to BLDC
2. Design of BLDC
3. Design through Software
4. Analysis
3 August 2020 carunaiselvane@gmail.com 2

Introduction
Internal combustion
Alternative fuel
Characteristic engine
vehicles (AFVs)
(ICE)
Number of moving parts Very high Low
Reliability Moderate High
Low High
Efficiency [%]
(less than 45) (more than 90)
No Yes
Bidirectional (can not rotate and (can rotate and generate
generate torque in reverse) torque also in reverse)
Energy recuperation No Yes
High
Power density [kW/kg] Low
Torque output at standstill No Yes

Noise, vibrations Moderate Low
High
Exhaust gas pollutants None
(CO, HC, NOx, PM)

Introduction
 Alternative fuel vehicles (AFVs) - hybrid electric vehicles

(HEVs), electric vehicles (EVs), fuel cell electric vehicles
(FCEVs)
AFVs electric drive system
Energy storage Electronic Power

Motors
systems controller converters
Battery and/or Sensors, Semi Permanent

ultra capacitors circuits, and conducting magnet
processors devices special
machines

BLDC fundamentals
 BLDC motors - since 1962.

 In recent years, PMBLDC have gained popularity.
 Area – precision control applications.
 Low noise and vibration, longer life and easy
controllabilty.
 High efficiency.
 These advantages, combined with the programmed
control have made them very attractive candidates
for various domestic and industrial applications.

BLDC fundamentals
 Brushless DC motor – without brushes, slip rings or

mechanical commutator.
 Type of Synchronous motor.
 Magnetic field generated by stator = rotor at same
frequency.
 Configurations – single phase, 2 phase and 3 phase.
 Most popular – 3 phase.

Structure of BLDC
Stator
Stator
Winding
Hall
Effect
Sensor
Shaft
Ball
Permanent Magnet
Bearing
Rotor
Stator
Stator- same as
3phase induction
motor Stamping
with
 Slots in interior slots
surface.
 Either open or closed
distributed armature
winding.
 Wounded for a Stator
specified no. of poles. windings
 Connected to a dc
supply power
electronic switching
circuit.

Rotor
 Rotor – permanent magnet instead of windings /cage
bars
 No. of poles in stator = No. of poles in rotor.
 Rotor shaft has rotor position sensor.
 Sensor provides suitable signals to electronic
commutator.

Hall sensors
 BLDC motor – electronically commutated.

 Rotation – stator windings are energized
sequentially.
 Hall effect sensors, senses the rotor position.
 As magnetic poles pass near hall effect sensor
 They give high or low signal.
 Indicating the N or S pole.
 Thus sequence of commutation determined.

Working
The angle - fixed to 900 (electrical).
Magnetic field generated , stator =
rotor.
Torque – interaction between stator
magnetic field and rotor.
Continuous running – magnetic
field produced by windings
should shift position, as rotor
moves.
Firing sequence - rotor position
information supported by Hall
Effect sensors.
Drive System

Example BLDC Motor Operation
This example BLDC motor has:
An external, electromagnet stator, with magnetic
field sensors.

Speed Vs Torque characteristics
This example BLDC motor has:

2 hp (1.5kW) 36V/48V
3000rpm.

Merits
No field winding – no Cu loss.
Possible to have very high speed.
Can be operated in hazardous atmospheric
condition.
Efficiency is better.
It is self starting motor.
Regenerative braking is possible.
Motor size is less.

De Merits
High cost.
Requires controller.
Greater motor drive complexity.
Setback – Cogging torque.

Comparison
Permanent Stepper Motor Brushless DC

Magnet DC Motor Motor
Advantages: - Low cost (high - Position - High efficiency
volume) control (low - High reliability
- Simple operation cost control - Low EMI
circuits) - Speed control
Disadvantages: - Medium - Poor - Maybe higher
efficiency efficiency cost
- Poor reliability - Digital - Complex
- Bad EMI interface control

Comparison
BLDC PMSM
Construction Synchronous machine Synchronous machine
Input Fed with DC Fed with AC
Back emf Trapezoidal Sinusoidal
Stator flux position Commutation each 60o Continuous variation
Excitation Two phases at a time All three phases at a time
Torque ripple High Less
Less
Harmonics Audible range (low order) Less
Less
Core loss High Low
Low
Switching loss Less High
Control algorithm Simple Complex

Set back
 Major set back - cogging torque.
 Detent or 'no-current' torque.
 Cogging Torque - interaction between the rotor
magnets and the stator slots.
 Result - vibration and deformation.
 Position dependent.
 Periodicity per revolution depends on the number of
magnetic poles and the number of teeth on the
stator.
 Prominent at lower speeds, with the symptom of
jerkiness.
Cogging Torque
 Cogging torque - torque as well as speed ripple.

 At high speed ,moment of inertia filters cogging
torque.
 In EVs - high output torque ripple and a rough
running motor.
 Non-ideal manufacturing - influence the cogging
torque profile.
 Therefore Cogging torque reduction is one of the
most important requirements.
 Direct impact on the performance of the motor.

Applications
Constant loads
Varying loads Applications
Positioning applications

Applications
Constant loads Varying loads Positioning
Load is Load on Most of the

directly motor varies industrial
coupled with over a speed and
motor shaft range automation
Eg : fans, Eg : washers, come under
pumps and dryers and this category
blowers compressors

Design of BLDC
 To design a BLDC.
 Independent / input variables – dimensions ,
winding turns and magnet materials.
 Dependent / output variables – torque, current,
efficiency, temperature rise, etc…
 Many independent variables – Requires reiteration
method.
 Process continues until desired performance
achieved.
 Individual steps in design process, easy.
 Comprehensive design – hundreds of parameter and
thousands of iteration, challenging.
Design procedure
The Rotor and Permanent

Magnet configuration
Course of
The Stator
Action
Winding

Decisions to be made
 Type of BLDC motor.

 Different magnetic materials.
 Method of commutation.
 Choice of rotor.
 Rough idea on magnet grade.
 Number of phases, poles and stator slots.
 Winding configuration.

Dimensions of BLDC
Slot depth
Stator outer
diameter
Rotor Rotor inner

outer diameter
diameter
Stator inner
wst – slot width
Magnet top
diameter
wt – tooth width
thickness
wbi – back iron length
ds – slot depth
wsb – slot width bottom
Air Gap
Complete BLDC
Stator Core
Stator Winding
Stator Teeth
Stator Pole Shoes

Rotor Core
Permanent
Magnet

Design - Flow chart
Application requirement
Rotor type
Magnet grade
Number of poles
No. of stator slots and

phases
Rough size
Air gap length and magnetic

loading
Design- Flow chart
Determine flux/pole
Stator lamination Dimensions
No. of Conductors & turns/coil
Wire size, resistance and

inductance/coil
Calc. performance
Temp. rise, current density, flux

densities, demagnetization of
3 August 2020 magnet
carunaiselvane@gmail.com 31
Rotor design
 Interior rotor, exterior rotor or axial gap
configuration?
 Axial rotor : fairly low speed, constant speed or
slightly variable speed.
Example: CD players, floppy discs and VCR’s
 Interior rotor : high-torque, low speed.
 Exterior rotor: higher speed which is constant or
varies only slightly.

Magnet grade

Number of Poles
Magnet material and grade
Interior-rotor vs exterior-rotor vs axial-gap rotor
Mechanical assembly of the rotor and magnets
Speed of rotation
Inertia requirements

Slot/Pole combinations
For 2 phase motors
Slots 8 12 16 20 24
Poles 2 2 2 2 2
6 10 4 6 4
6 14 6
10 10
12 18
14 20
Reference :
R.Hendershot Jr. and TJE Miller, Design of Brushless Permanent-Magnet
Motor. Magna Physics Publications & Clarendon Press, 1994, Oxford.

Slot/Pole combinations
For 3 phase motors
Slots 3 6 9 12 15
Poles 2 2 2 2 2
4 4 4 4 4
6 8 10
8 10
12 18
Reference :
R.Hendershot Jr. and TJE Miller, Design of Brushless Permanent-Magnet
Motor. Magna Physics Publications & Clarendon Press, 1994, Oxford.

Winding pitch
 Final point – Winding Pitch.
 Winding pitch = No. of Slots / No. of poles.
 Rounded off to next lower number.
Slots/Pole Coil span in slot-pitches
0.75 1
1.5 1
2.25 2
3 3
3.75 3

Slot/Pole ratio
For 3 phase Brushless Motors
0.75 1.5
Slots Poles Slots Poles
3 4 3 2
6 8 6 4
9 12 9 6
12 16 12 8

Windings
 Interior rotor - Lap windings and Concentric
windings.
 Lap winding – similar to 3 phase induction motors.
 Concentric winding – similar to shaded pole motors.
 Exterior rotor – Similar to DC motor armature
windings except for terminal connections and
number of lead.
 Winding configurations.

Windings
 First step, (N slots / 2p) = σmax +ε .
where, N slots – Stator slots
2p – Rotor poles
σmax – Maximum Coil span
ε – Fractional number of slot – pitches
 Location of subsequent coils,
 Slot forward, SF = σmax +1, if ε ≤ 0.5
= Nss - σmax , if ε > 0.5
 Number of slots/section, Nss =(N slots )/HCF[Cph , p]
 SF = σmax +1, winding is progressive (CCW)
 SF = Nss – σmax , winding is retrogressive (CW)

Coil list
3 phase motor with 15 slots and 4 poles

Coil no. Turns Go Slot Return Coil Span
1 12 1 3 2
2 12 7 5 -2
3 12 9 11 2
4 12 15 13 -2
5 12 2 4 2

Publication

MagNet
 2D and 3D models for magnetostatic, time
harmonic, transient or transient with motion
analysis.
 Provide accurate field solution – finite element mesh

Structures
 Machines : DC, Universal, 3phase IM
 Actuators
 Solenoids
 Loudspeakers
 Transformers
 Sensors
 Recording heads

Flowchart
Open a new model
Set the drawing space

Build the
Draw the geometry
geometric model
Sweep the components
Apply the Make Simple Coil or Make Multi-
terminal Coil commands to the coil components
Create coils
Edit the coil properties
Draw and sweep an air box that surrounds the
Add boundary model
conditions
Apply boundary conditions to surface
Modify the mesh edge subdivisions
Customize mesh
(optional)
Modify the mesh edge length
Choose the solver options (or accept the defaults)
Solve
Choose the adaption options (optional)
View field plots and field animations
View the solution
View and graph global quantities
results
Probe filed values

Drawing edges

Drawing lines
 Mouse.
 Keyboard input bar.

Drawing arc

Drawing circle

Making components

Changing components properties

Selecting

Materials

Results
 Total magnetic stored energy and co-energy.

 Force and torque on each body.
 Flux linking each coil.
 Ohmic loss in each conducting component.
 Iron loss for each enabled component.
 Current in each coil and circuit component.

MagNet

MagNet

MagNet

MagNet

Magnet

MagNet

MagNet

MagNet

MagNet

MagNet

MagNet

Existing commercial model

Real model

Outline

Material filled

Side view

Coil

2D mesh analysis

Flux pattern

Flux pattern

Analysis

Analysis

Analysis
MOOG G400Series
Flux Linkages
Rotor position Time Cogging Torque
r y b
0 0.0 0.270754204 0.00901354 0.001905281 0.00175048
20 0.3 0.134496334 0.01419781 0.001276099 0.00154995
40 0.7 0.037535552 0.01222439 0.001472668 0.00153602
60 1.0 -0.012757085 -0.0082936 0.001286526 0.00212937
80 1.4 0.061525324 -0.0076572 0.001931811 0.00142436
100 1.7 0.059994474 0.01297295 0.001355804 0.00153879
120 2.1 0.030713514 0.0140539 0.001581282 0.00127302
140 2.4 -0.242976567 -0.0018839 0.001427326 0.00174912
160 2.8 0.144749316 -0.0090604 0.001664933 0.00156034
180 3.1 0.457679947 0.00157195 0.001689735 0.00146293
200 3.5 0.139912581 0.01416093 0.001262013 0.00155589
220 3.8 0.0551138 0.01228999 0.00149548 0.00147565
240 4.2 0.119154752 -0.0082783 0.001310257 0.00214766
260 4.5 0.181870727 -0.007644 0.001949407 0.00142172
280 4.9 0.170530962 0.01302303 0.001353665 0.0015173
300 5.2 -0.203269645 -0.0018704 0.001418748 0.00175293
320 5.6 -0.098226274 -0.0076868 0.001470409 0.00194071
340 5.9 0.144749316 -0.0090604 0.001664933 0.00156034
360 6.3 0.457679947 0.00157195 0.001689735 0.00146293
Cogging Torque analysis
MOOG G400Series
Rotor position Time Cogging Torque
0 0.0 0.270754204
20 0.3 0.134496334
40 0.7 0.037535552 Cogging Torque
60 1.0 -0.012757085 0.5
80 1.4 0.061525324
0.4
100 1.7 0.059994474
120 2.1 0.030713514 0.3
140 2.4 -0.242976567 0.2
160 2.8 0.144749316
0.1 Cogging Torque
180 3.1 0.457679947
200 3.5 0.139912581 0
220 3.8 0.0551138 0 50 100 150 200
-0.1
240 4.2 0.119154752
260 4.5 0.181870727 -0.2
280 4.9 0.170530962 -0.3
300 5.2 -0.203269645
320 5.6 -0.098226274
340 5.9 0.144749316
360 6.3 0.457679947
Research gaps
 At present, there are still challenging problems in the

electric drive system.
 Battery/capacitors - Long charging times.
 Sensors - Rotor position error.
 The motor runs under bad conditions, e.g., the vehicle
engine vibration and high-temperature environment -
reliable, stable, and safe operation.
 Machine design improvement - Due to space limitations,
high-density, compact, and lightweight.
 Reduction of switches in power circuit.

Dr. CARUNAISELVANE.C
Indian Institute of Technology
Hydropower Simulation Laboratory
Roorkee, India.
carunaiselvane@gmail.com
+91 8265804594
https://scholar.google.com/citations?user=lmvjiSUAAAAJ&hl=en
https://www.researchgate.net/profile/Carunaiselvane_Carounagarane
https://www.linkedin.com/in/dr-carunaiselvane-c-88b41723/
Thank you all for your attention
Carunaiselvane Carounagarane (S’16) received the B.Tech. degree in electrical and electronics engineering
and the M.Tech. degree in electrical drive and control from Pondicherry Engineering College, Pondicherry
University, Puducherry, India, in 2008 and 2012, respectively. He has received the Ph.D. degree from
Indian Institute of Technology Roorkee, India in 2020 under the title “Analysis of Large Hydrogenerators
Operating at Continuous Overloads”. He is currently working as Research Associate with the Hydropower
Simulation Laboratory, Department of Water Resource Development and Management, Indian Institute of
Technology Roorkee, Roorkee, India. From 2008 to 2010, he was an officer grade Electrical Engineer with
Larsen and Toubro Pvt. Ltd., India. From 2012 to 2014, he has been an Assistant Professor with the
Electrical and Electronics Engineering Department, Sri Manakula Vinayagar Engineering College, Pondicherry
University. His research interests include electrical machines, power electronics, machine design, large
hydromachine drives and controls, and renewable and sustainable energy. Dr. Carunaiselvane has presented
many research papers in various national and international conferences and journals.
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Design Aspects of BLDC Motor and MagNet Software

Presentation · August 2020

Analysis on Large Hydrogenerators Operating at Continuous Overloads View project

The user has requested enhancement of the downloaded file.

3. Design through Software

3 August 2020 carunaiselvane@gmail.com 2

Torque output at standstill No Yes

3 August 2020 carunaiselvane@gmail.com 4

 Alternative fuel vehicles (AFVs) - hybrid electric vehicles

Energy storage Electronic Power

Battery and/or Sensors, Semi Permanent

3 August 2020 carunaiselvane@gmail.com 5

 BLDC motors - since 1962.

3 August 2020 carunaiselvane@gmail.com 6

 Brushless DC motor – without brushes, slip rings or

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3 August 2020 carunaiselvane@gmail.com 10

 BLDC motor – electronically commutated.

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This example BLDC motor has:

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Permanent Stepper Motor Brushless DC

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 Cogging torque - torque as well as speed ripple.

3 August 2020 carunaiselvane@gmail.com 21

Varying loads Applications

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Constant loads Varying loads Positioning

Load is Load on Most of the

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The Rotor and Permanent

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 Type of BLDC motor.

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Rotor Rotor inner

Stator Pole Shoes

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No. of stator slots and

Air gap length and magnetic

Stator lamination Dimensions

No. of Conductors & turns/coil

Wire size, resistance and

Temp. rise, current density, flux

3 August 2020 carunaiselvane@gmail.com 32

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Magnet material and grade

Interior-rotor vs exterior-rotor vs axial-gap rotor

Mechanical assembly of the rotor and magnets

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Slots/Pole Coil span in slot-pitches