A SENSORED MOTOR is a type of brushless DC motor (BLDC) with built-in position sensors. Its core design involves using sensors (such as Hall elements or encoders) to monitor the rotor position in real-time and feed the signal back to the controller, thus enabling precise control of current commutation. Unlike sensorless motors that estimate the rotor position based on back electromotive force, sensor-equipped motors significantly enhance low-speed performance and operation stability by directly detecting changes in the magnetic field.
Core Advantages: Why Choose a Sensor-equipped Motor?
Excellent Low-speed Performance
When approaching zero rotational speed, the sensor can accurately capture the rotor position, avoiding jitter or step loss during startup. For example, when a remote-controlled car is drifting or an electric tool is drilling at a low speed, it can achieve smooth startup and stable torque output.
High-precision Control
The sensor provides real-time position feedback, allowing the controller to precisely adjust the current phase, making it suitable for scenarios that require dynamic response, such as the control of a drone’s gimbal or the joints of an industrial robotic arm.
Strong Anti-interference Ability
In the event of sudden load changes or magnetic field interference (such as when there are large-current devices nearby), the sensor signal can help the controller quickly correct the commutation strategy, reducing the risk of losing control.
Compatibility and Flexibility
It supports multiple control modes, and some high-end models can be switched to the sensorless mode, balancing the needs of low cost and high-performance scenarios.
Typical Application Scenarios
Remote Control Models (RC) and Competition Equipment
For example, racing drones and drifting remote-controlled cars rely on sensors to achieve millisecond-level throttle response and precise torque distribution.
Power Tools and Home Appliances
For equipment like electric drills and angle grinders that require low-speed and high torque, sensors ensure smooth start and stop; high-end washing machines and air conditioning fans utilize their low-noise characteristics.
Industrial Automation
In conveyor belts, robotic arms, and medical equipment (such as surgical robots), sensor-equipped motors provide reliable start and stop precision and a long service life.
New Energy and Transportation
In the electric power steering (EPS) of electric vehicles and the hub motors of electric bicycles, sensors are relied on to ensure safety and energy efficiency.
Key Differences from Sensorless Motors
Low-speed Performance
Sensor-equipped Motor: No jitter during startup, stable low-speed torque, suitable for precise control.
Sensorless Motor: May experience step loss at low speeds due to weak back electromotive force signals, and needs to “guess blindly” for commutation, prone to stuttering.
Cost and Complexity
Sensor-equipped Motor: Due to the need for sensors and additional wiring, the cost is higher, and maintenance is more complex (for example, if the Hall element is damaged, it needs to be replaced).
Sensorless Motor: Simple structure, low cost, suitable for high-speed operation or scenarios with limited budgets (such as fans, ordinary drones).
Applicable Environments
Sensor-equipped Motor: Strong anti-interference ability, suitable for scenarios with dynamic loads or complex electromagnetic environments.
Sensorless Motor: More suitable for stable high-speed operation (such as high-speed electric spindles) or mass-produced products that are sensitive to cost.
Technical Trends and Purchase Suggestions
Technological Development
New magnetic encoders are gradually replacing traditional Hall sensors, offering higher precision and better high-temperature resistance.
Integrated design (such as embedding the sensor in the controller) reduces wiring and lowers costs.
Purchase Key Points
Clearly Define Requirements: If low-speed and high-precision performance is required (such as in robots, medical equipment), give priority to sensor-equipped motors; if high speed or low cost is pursued (such as in home appliances), sensorless motors are more suitable.
Compatibility Verification: Confirm that the controller supports the signal protocol of the sensor (such as PWM, SPI, or ABZ encoding).
SENSORED MOTOR plays an important role in various demanding scenarios because it can provide precise control and stable low-speed performance. Although it has higher cost and complexity, it is almost indispensable in applications that require reliability, fine operation, or in complex environments. With the continuous progress of sensor technology and the application of intelligent algorithms, SENSORED MOTOR will play an even more important role in fields such as autonomous driving and smart homes, and become the core choice for high-efficiency drives.