When running smart home and industrial automation equipment, have you ever encountered problems such as motor jitter, loud noise, and even affecting the accuracy of the equipment at low speed? Behind this, the low-speed torque pulsation of BLDC motor is the key “crux”. Whether it is the stable operation of precision instruments or the quiet requirements of smart home appliances, torque pulsation may lead to reduced equipment performance and shortened life. This article will deeply analyze 5 innovative solutions to help you find the “optimal solution” to optimize the performance of BLDC motors.
Troubles and causes of low-speed torque pulsation
When BLDC motors run at low speed, the jitter and noise caused by torque pulsation greatly reduce the stability of the equipment. In 3D printers, torque pulsation can cause uneven printing layers; in fan motor applications, it produces annoying humming sounds. What’s more serious is that frequent torque fluctuations will accelerate the wear of mechanical parts, increase maintenance costs, and even affect the realization of the core functions of the equipment. The root cause of this problem lies in the limitations of motor design and control mechanisms. The distortion of the back EMF waveform, the magnetic resistance caused by the slot effect, and the insufficient current control accuracy will all lead to unstable torque output. At the same time, the traditional control algorithm has a delayed response in the low-speed range and cannot compensate for torque fluctuations in real time, further exacerbating the severity of the problem.
Performance breakthrough of five innovative solutions
Adopting advanced field-oriented control (FOC) algorithm optimization, the torque pulsation can be reduced by more than 30% by accurately adjusting the phase and amplitude of the three-phase current. Improving the motor structure design is also critical. For example, the use of skewed slot rotors and fractional slot windings can effectively weaken the slot torque. After optimization, the low-speed operation noise of a drone motor is reduced by 25 decibels. Introducing artificial intelligence predictive control, dynamically adjusting the control strategy based on historical data and real-time feedback, so that the motor remains stable under complex working conditions. Multi-harmonic injection technology offsets the inherent torque pulsation component by superimposing current harmonics of specific frequencies. In addition, optimizing the accuracy of the position sensor and cooperating with high-precision analog-to-digital conversion chips can achieve sub-millisecond detection of the motor rotor position, providing a basis for precise control.
The value and implementation path of the solution
Solving the BLDC low-speed torque pulsation can not only improve the stability and quietness of equipment operation, but also extend the service life of the motor and reduce maintenance costs, unleashing huge application potential in high-end manufacturing, smart home and other fields. The implementation can be divided into three steps:
(1) Evaluate the adaptability of the five solutions according to the application scenario requirements, such as optimizing the structure of noise-sensitive home appliances and combining them with FOC;
(2) Build an experimental platform to simulate and test the selected solutions and fine-tune the parameters;
(3) Complete small-batch production verification, and iterate and optimize through actual operation data to ensure that the solution is stable and reliable.
The five innovative solutions, from algorithm optimization to structural innovation, provide multiple paths for overcoming BLDC low-speed torque pulsation. Whether it is equipment manufacturers pursuing performance upgrades or engineers exploring technological breakthroughs, it is crucial to choose the right solution and put it into practice. Take action now, compare the advantages and disadvantages of the solutions according to your own needs, start the journey of BLDC motor performance optimization, and inject new momentum into equipment quality upgrades!