Optimal Design Strategy for Improved Operation of IPM BLDC Motors With Low-Resolution Hall Sensors

This study proposes an interior permanent magnet (IPM) brushless dc (BLDC) motor design strategy that utilizes BLDC control based on Hall sensor signals. The magnetic flux of IPM motors varies according to the rotor position and abnormal Hall sensor problems are related to magnetic flux. To find the cause of the abnormality in the Hall sensors, an analysis of the magnetic flux density at the Hall sensor position by finite element analysis is conducted. In addition, an IPM model with a notch structure is proposed to solve abnormal Hall sensor problems and its magnetic equivalent circuit (MEC) model is derived. Based on the MEC model, an optimal rotor design method is proposed and the final model is derived. However, the Hall sensor signal achieved from the optimal rotor is not perfect. To improve the accuracy of the BLDC motor control, a rotor position estimation method is proposed. Finally, experiments are performed to evaluate the performance of the proposed IPM-type BLDC motor and the Hall sensor compensation method.