Design and prototyping of 3-phase BLDC motor

Abstract

The development of electric vehicle is now growing rapidly. Demands to deliver a reliable and easy to drive in motor control causes Brushless Direct Current (BLDC) motor becomes a potential candidate. A BLDC motor drive is a potential option for an electric vehicle since it has a high reliability, simple design, and ability to work at high rotation per minute (RPM). This paper discussed the Permanent Magnet BLDC Motor design method. The structure of an interior rotor permanent magnet type is selected to be used in the design of Permanent Magnet BLDC motor so that it can be applied in a drive that requires a large torque and capable of acceleration and deceleration with good response. Selection of 12 slots and 8 poles configuration aims for improving the motor performance. The motor is designed and simulated using a software-based Motor Solve FEA (Finite Element Analysis). Based on this design and simulation results, a prototype of BLDC motor is built. Parameters testing as stator resistance, inductances (the d-axis and q-axis inductance), and the back emf constant (Ke) were used to evaluate the result of the design and prototype motor. Measuring the prototype motor's parameters was carried out by several different methods depending on the parameters tested. Stator resistance testing is performed with the measurement of current in the coil which is then obtained by calculating the magnitude of stator resistance as 0.14710296 Ω. Measurements of d-axis stator inductance, q-axis stator inductance, and back emf constant of prototype permanent magnet BLDC motor is obtained as results of 0.35304710 mH, 0.38246769 mH and 0.09690626 Vs/rad respectively. The test results between design and prototype testing were quite good. The difference between the test results and the design of the prototype test results was caused by incompatibility of material composition although using the same type of material. The evaluation shows the electromagnetic parameters is influenced by its constituent materials.