Design and control of brushless DC motor

Permanent Magnet Brushless DC (BLDC) motors are the most used machines in the world industry compared to other motors. These motors are generally used for small and medium power. The reasons why BLDC motor are preferred in many areas; is the absence of commutator, has high efficiency, requires less maintenance, has small size, and works at high speed. Overall the objects of this project are to produce a developed prototype BLDC motor with distributed windings. Moreover, maximum power and torque density per mass, the use of less magnetic materials and lower cost of control card are additional purposes. In this study, the dimension, magnetic equivalent circuit, and electrical equivalent circuit parameters are analytically calculated. Using the obtained parameters, power loss, output power and output torque values are known. After finishing the analytical design, Genetic Algorithms (GA) were used as optimization methods to obtain better results. The Ansys-Maxwell program, based on the finite element method (FEM) for motor analysis, is used, and the prototype evaluated motor has a rated output power of 258w and a nominal speed of 1800rpm. Brushless DC Motor (BLDC) Field Oriented Control (FOC) is one of the most commonly used methods for motor torque control. A BLDC drive system is designed, simulated and implemented based on FOC. The entire drive system is simulated in Matlab / Simulink using mathematical models of the devices used in the system, namely BLDC and driver. The driver's intent is to have speed control over a wide range of speeds. The simulation results show that the speed controller has a good dynamic result.