What is a Brushless DC Motor?
A Brushless DC Motor
 (also known as a BLDC Motor), is a synchronous electric motor powered 
by a direct current. As the name implies, the Brushless DC Motor does 
not operate using brushes; rather it operates with a controller via 
electronic commutation.
Block Diagram for a Brushless DC Motor
 
         
        
 
How does a Brushless DC Motor Work?
A Brushless DC Motor is operated by 
means of an electronic six-step commutation system. Unlike its Brush DC 
Motor counterparts, the Brushless DC Motor does not contain any carbon 
brushes. Instead, the electromagnets within the motor remain stationary 
along with the armature, while the encased permanent magnets rotate, 
generating torque. The Brushless DC Motor is synchronous; both the 
stator and the magnetic field generate the same frequency, therefore 
avoiding any type of “slip” most induction motors exhibit.
What is Six-Step Commutation?
        
Six-step commutation is a cost-effective
 means of electronic commutation, due to the simple and relatively 
inexpensive feedback and drive devices. In six-step commutation, only 
two out of the three Brushless DC Motor windings are used at a time. 
Steps are equivalent to 60 electrical degrees, so six steps makes a 
full, 360 degree rotation. One full 360 degree loop is able to control 
the current, due to the fact that there is only one current path. 
Six-step commutation is typically useful in applications requiring high 
speed and commutation frequencies. A six-step Brushless DC Motor usually
 has lower torque efficiency than a sine-wave commutated motor.
How is a Brushless DC Motor Controlled?
An electronic Brushless DC Controller
 (also known as a Driver, or Electronic Speed Controller), replaces the 
mechanical commutation system utilized by a Brush DC Motor, and is 
required by most Brushless DC Motors to operate. In a Brushless DC Motor
 controller, either a Hall Effect Sensor or Back EMF (Electromotive 
Force) is used to identify the position of the rotor. Understanding the 
orientation of the rotor is crucial to operating the Brushless DC Motor.
  
		
		The Hall Effect uses three hall sensors within the Brushless DC Motor 
to help detect the position of the rotor.  This method is primarily used
 in speed detection, positioning, current sensing, and proximity 
switching.  The magnetic field changes in response to the transducer 
that varies its output voltage.  Feedback is created by directly 
returning a voltage, because the sensor operates as an analogue 
transducer.  The distance between the Hall plate and a known magnetic 
field can be determined with a group of sensors, and the relative 
position of the magnet can be deduced.  A Hall sensor can act as an 
on/off switch in a digital mode when combined with circuitry.  
		
		Back EMF, also known as the Counter-Electromotive Force, is caused by a
 changing electromagnetic field.  In a Brushless DC Motor, back EMF is a
 voltage that occurs where there is motion between the external magnetic
 field and the armature of the motor.  In other words, the voltage is 
developed in an inductor by an alternating or pulsating current.  The 
polarity of the voltage is constantly the reverse of the input voltage. 
 This method is commonly used to measure the position and speed of the 
Brushless DC Motor indirectly, and due to the lack of Hall Sensors 
within the controller, these are often referred to as sensorless 
controllers.
		
		Optical Encoders
 can also be added to the Brushless DC Motor, allowing both direction 
and speed to be determined. More precise applications may use Optical 
Encoders with a third index signal, to determine pulse per revolution.
Physical Properties of a Brushless DC Motor
        
The Brushless DC Motor consists of a 
rotating rotor, Neodymium Iron Boron magnets, and a stator. Brushless DC
 Motors are considered to be an “inside-out” version of a Brush DC 
Motor; the commutator and brushes are nonexistent, and the windings are 
located externally, connected to the controller. There are typically two
 different construction types for the Brushless DC Motor: inrunner and 
outrunner configurations. The inrunner configuration consists of three 
stator windings located around the rotor, with permanent magnets as a 
part of the rotor. The outrunner has a reversed relationship between the
 magnets and the coils. The permanent magnets rotate inside a suspended 
rotor surrounding the core of the Brushless DC Motor. 
		
		Internally, a 3-phase motor can be configured to a “Wye” or “Delta” 
configuration.  The primary advantage to the “Wye” configuration, also 
known as the Star configuration, is that the phase-to-neutral voltage is
 equal in all three legs. The arrangement is a parallel circuit in a 
shape of the letter Y, where all windings are connected at a central 
point, and power is applied to the remaining windings.
 
The Delta configuration creates a 
triangle-like figure, making it a series circuit. This configuration 
applies power to each of the connections.
 
How to Select a Brushless DC Motor
Selecting the appropriate Brushless DC Motor
 requires knowing the requirements of the application, such as torque, 
speed, size, power, length, etc. While determining which Brushless DC 
Motor best fits the requirements, the controller must be considered as 
well, as this goes hand in hand with the operation of the Brushless DC 
Motor. 
		
		Lastly, environment is important to consider. Applications requiring a
 harsh, damp environment may require motors with specific IP ratings. 
For more detailed information on this subject, see Brushless DC Motor 
Environmental Considerations.
Brushless DC Motor Applications
The cost of the Brushless DC Motor has 
declined since its introduction, due to advancements in materials and 
design. This decrease in price, coupled with the many advantages it has 
over the Brush DC Motor, makes the Brushless DC Motor a popular 
component in many different applications. Applications that utilize the 
Brushless DC Motor include, but are not limited to:
 
        
| • Instrumentation | 
| • Medical | 
| • Appliances | 
| • Automotive | 
| • Factory Automation Equipment | 
| • Aerospace | 
| • Military | 
Advantages of a Brushless DC Motor
The absence of brushes in a Brushless DC Motor
 is perhaps its greatest advantage. The carbon brushes within a Brush DC
 Motor wear out rapidly and need replacing, which can be costly in the 
long run. The Brushless DC Motor generates less noise, and is less prone
 to sparking due to the lack of a commutator. The Brushless DC Motor is 
typically smaller and lighter than the Brush DC Motor,
 making it ideal for applications where weight and space are important 
factors.  The Brushless DC motor is cleaner, more powerful, and requires
 lower maintenance than does the Brush DC Motor. It has higher speed 
ranges, higher dynamic responses, and ultimately outlasts the Brush DC 
Motor in total operating hours.
Disadvantages of a Brushless DC Motor
There are numerous applications using a Brush DC Motor
 that could instead utilize the Brushless DC Motor. However a few 
factors might prevent the changeover. The first factor is start-up cost.
 Although the Brushless DC Motor is lower-maintenance than the Brush DC 
Motor, initial cost is more expensive, due to its advantageous 
construction. Second is complexity. A controller is required in order to
 operate a Brushless DC Motor, and is usually more convoluted than most 
controllers. A Brushless DC Motor also requires additional system 
wiring, in order to power the electronic commutation circuitry.
Lifetime of a Brushless DC Motor
The Brushless DC Motor is often considered 
superior over the Brush DC Motor for its substantially longer lifespan. 
If run within the given specifications, the Brushless DC Motor can last 
over 20,000 operating hours based on bearing life. Running a Brushless 
DC Motor outside of its specifications shortens this lifespan.
Required Maintenance of a Brushless DC Motor
Due to the lack of brushes or a commutator, 
there is nothing to replace within a Brushless DC Motor, making it 
extremely low maintenance. The only requirement is that the motor be run
 within proper specifications, and in a clean environment to ensure it 
does not overheat or result in system failure.
Brushless DC Motor Environmental Considerations

		Precaution must be taken by the user with 
respect to the environment of the Brushless DC Motor system during 
operation, repair, and service. The environment in which a Brushless DC 
Motor is used, must be conducive to good general practices of electrical
 equipment. Do not run a Brushless DC Motor system near flammable gases,
 dust, oil, vapor or moisture. The Brushless DC Motor must be protected 
by a cover if operated outdoors, ensuring the motor receives adequate 
air flow and cooling. Any presence of moisture may result in system 
failure and/or electric shock. Therefore adequate care should be taken 
to avoid any interaction between the Brushless DC Motor and any kind of 
moisture or vapors. A Brushless DC Motor should be installed in an 
environment free from vibration, shock, condensation, dust and 
electrical noise.
Formulas
What is the Kt Constant in a Brushless DC Motor?
Winding Power = Kt*Kt/R
		
		Kv = 1000 rpm / Vrms
		
		Kt = oz-in / Amp
		
		Kt = Kb * 1.35
		
		Ke = Vrms / 1000 rpm
		
		Kb = V / 1000 rpm
		
		Back EMF = V/KRPM