Design and analysis of planetary reductor spoke type brushless direct current motor

Today, Brushless Direct Current Motors (FDAM) are widely used in many applications due to their high efficiency, long life, high starting performance and compact structure. In this thesis, a spoke type FDAM design with planetary reducer and 12/10 corrugated pole combination was made to be used in valve applications. Neodymium magnet was preferred in the spoke type rotor structure due to the lower magnet volume and knocking torque. Planetary gear systems have many advantages compared to conventional gearboxes such as speed, small volume, high load sharing and torque-to-weight ratio. Planetary gear systems have higher efficiency in small volumes due to the compact gear combination. For this reason, planetary reducer is preferred in this study. The design was verified by making Finite Element Analyzes according to the electrical and magnetic parameters of the predicted FDAM. During the design and modeling process, motor speed, load torque, mechanical and electrical power, losses, magnetic flux and current densities were taken into account. Prototype manufacturing of a 10-pole neodymium magnet motor and planetary reducer, whose design has been verified, has been made. In manufacturing, stator and rotor laminations are laser cut from M400-50A sheets. Nd35SH magnets are used. The body and covers are produced by machining and the winding is made by hand. Loading tests were carried out by connecting the motor to the test system as a free shaft. TI development kit was used as a driver in the tests and it was tested at different loads by being fed from a DC source. Nameplate values were determined according to the analysis and test results of the engine. Accordingly, the supply voltage is 200 VDC, the mechanical power is 400W, the speed is 1800 rpm, the torque is 2.12 Nm and the maximum motor test efficiency is 75%. With the planetary gearbox used in the application side with a ratio of 1/9, a product that can function in the valve with an output torque of approximately 19 Nm and a speed of 200 d/d has been obtained.