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Our developments in Brushless DC Motor (BLDC) technologies
and Inverter Drive systems since 1997 has concentrated on
cooling fan applications within train control equipment cabinets
and within a new concept in motorized golf buggy wheels.
In our developments, various frame sizes were designed and
constructed for individual requirements.
The applications for this technology were recognized as potentially
limitless and open to the larger audience over and above the
market we have been addressing to date.
As a matter of urgency our engineers designed and constructed
a prototype BLDC motor of up to 2kW power with unique characteristics
that would ideally apply directly to universal Climate Control
Systems.
The versatility and robustness of our existing Inverter Drives
allowed easy adaptation for effective control of our new motor.
During our trials Initially on a commercially available Evaporative
Cooler, the major advantages of a direct drive system using
BLDC technology became immediately obvious.
As significant benefit to be gained with our prototype is
the sizes and power capacities of the BLDC motor and Drive
are scalable to suit custom applications. This provides the
opportunity to cost effectively produce optimum systems for
specific performance requirements.
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The following lists some of the technical, User and
cost advantages offered with our BLDC Motor Drive Systems:
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Long Operating Life - Having neither brushes
nor a segmented commutator, the life of a BLDC
extends well beyond that of a Brush Type. AC to
DC converters do not stress motor insulation with
high voltage peaks increasing potential motor
life.
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Clean Operation - Because it has no brushes,
the brushless DC motor emits no brush dust. As
such, it is well suited to clean room applications.
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Tolerant of Harsh Environments - The BLDC
emits no sparks during normal operation because
there is no exposed sliding contact between the
brushes and metallic commutator. Furthermore,
the "hard-wired" connections of a BLDC Motor can
be easily sealed so that the entire assembly can
operate safely while submersed in liquid
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Lower environmental impact - Simplicity
of AC to DC static converters with Unity Power
Factor Correction (PFC) optional using PFC controlled
AC to DC converter. Quieter operation than AC
counterparts through entire speed range. EMC EN50082-2/
EMI EN50081-1 attracts international markets
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Highly
Responsive - The high torque to inertia ratios
of brushless motors yield quick response to commands.
Low inertia characteristics allow faster response
times. |
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High Speed
- Lacking the limitations of conventional commutation,
brushless motors can be operated at very high speeds.
Transit has demonstrated electronic commutation
at speeds in excess of 40,000 rpm. |
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Low Thermal
Resistance - The windings of brushless DC motors
are located on their stationary member. Therefore,
heat may be carried away using direct conduction.
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Efficiency
- Gearbox, drive belts, pulley losses overcome.
Provides higher consistent efficiencies across speed
range providing significant energy savings. Lower
losses in cooling fan applications - introduces
less spurious heat. Wide speed range and high low
speed torque allows possibility of direct drive
applications resulting in further cost savings and
efficiency gains. |
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Other Features
- Compact size high power/ weight ratio. Battery
power practical up to 1 kW. Dynamic braking features
available. Sensorless Drive Electronics possible
giving further cost reductions. Over voltage and
Power/ Current limit protection, Universal power
supply compatible. Forward Reverse Control economically
implemented in all cases.( e.g. mechanical operation
of water drain valve on evaporative coolers ) |
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below illustrate the physical concept of our development
and a typical application. |
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Fig 1 Stator
complete - Designed and constructed using 3D modeling
concepts.Simple construction techniques and ease of installation
and setup. |
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Fig 2 BLDC motor installed
to fan - Direct Drive overcomes need for expensive
drive belts, pulleys and motor mount hardware |
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Fig 3 Close up of typical
motor installation - Reliability, performance and
efficiency are the key to sound economic change. No consumable
parts degradation… Long life bearings can perform for
more than 200,000 hours. |
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Fig 4 TECo 3 Phase BLDC Controller -
This model is a 600 W version controlling the fan shown
above. System Efficiencies over 70% across speed range,
with over 80% possible with Delta Wound Stator. |
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| Fig 3 Close up of
typical motor installation |
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| Fig 4 TECo 3 Phase
BLDC Controller |
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