When you use a silent fan or control a drone, sensorless BLDC motor technology may be at work behind the scenes. This technology that can accurately control speed without physical sensors is very popular, but how to overcome the difficulties of starting and running? This article will analyze the technical points and application trends for you.
Technical challenges: the dual challenges of precise control and stable operation
Although sensorless BLDC motor technology has significant advantages, it faces the dual challenges of starting and running. At startup, the lack of sensors to feedback the rotor position in real time can easily lead to motor start failure, jitter or even reversal; during operation, load changes and electromagnetic interference can cause rotor position estimation deviations, affect speed and torque output, and reduce equipment performance.
These problems are due to the complexity of technical principles. This technology relies on indirect signals such as back electromotive force and freewheeling diode voltage to estimate rotor position and speed. The signal is weak and difficult to capture at startup, and the complex magnetic environment and motor parameter changes during operation interfere with signal processing, making position estimation difficult.
Technical implementation: Multi-dimensional innovation breaks through technical bottlenecks
To solve the problem, engineers innovated from multiple dimensions of algorithms, signal processing and hardware design. At the algorithm level, advanced algorithms such as Kalman filtering and sliding mode observers are extended to handle interference in real time and accurately estimate the rotor position and speed. In signal processing, with the help of high-precision analog front-end circuits and digital signal processing technology, weak signals are amplified, filtered, and noise-reduced, and software algorithm correction is used to improve signal reliability. Hardware design optimizes windings and power circuits to reduce electromagnetic interference and provide a stable signal foundation for the algorithm.
Application prospects: Multi-field expansion and implementation guide
The breakthrough of sensorless BLDC motor technology has brought changes to multiple fields. In the field of home appliances, fans and air conditioners with quieter and more energy-saving functions can be realized; in the field of electric vehicles, the drive system can be simplified to reduce costs and increase efficiency; in the field of drones and robots, it helps to upgrade equipment to lightweight and intelligent.
The implementation of technology can be divided into four steps:
(1) First, clarify the product’s requirements for motor control accuracy and stability;
(2) Then select the appropriate algorithm and signal processing solution, and cooperate with the manufacturer to verify the design;
(3) Then carry out small-batch prototype testing to optimize parameters; and finally establish a quality inspection system to ensure the quality of large-scale production.
Sensorless BLDC motor technology breaks through control problems with innovation and shows great potential in many fields.
At a time when global technological competition is fierce, sensorless BLDC motor technology, as a key driving force for industry change, is reshaping the market landscape. For technology developers, in-depth research and mastery of this technology can not only seize the technological commanding heights, but also lay the groundwork for future product innovation; for product manufacturers, being the first to apply it to actual production can significantly reduce costs and improve product performance, thereby standing out in the fierce market competition. Therefore, technology developers and product manufacturers should keenly grasp this trend, actively invest in technology application and product upgrades, improve product competitiveness through continuous innovation, work together to promote technological innovation in the entire industry, and jointly write a new chapter in the development of the industry.