BLDC Motor Controller
Brushless Drivers/Controllers

Anaheim Automation's Brushless DC Controllers are designed for high-volume OEM applications, keeping a low unit cost as the primary objective. Covering a wide range of motors, these quality controllers are available in input power ranges from 6-50VDC or 85-135VAC. Choose from 0-5VDC analog input control, or simply turn a potentiometer - it's that easy! Providing peak power up to 1500 Watts and peak current up to 60Amps, these brushless DC controllers deliver unsurpassed performance and quality, at an affordable price! For information on a custom BLDC controller, contact an Anaheim Automation Applications Engineer.


  • Input Ranges: 6 to 50VDC
  • Max Power: 24 to 250 Watts
  • Peak Current: 3 to 10Amps
  • Low-Cost Speed Controllers
  • Covers a Wide Range of Motors
  • Printed Circuit Board Style
  • Overcurrent and Undervoltage Protection
  • Input Ranges: 10 to 50VDC or 85 to 135VAC
  • Max Power: 36 to 500 Watts
  • Peak Current: 3 to 60Amps
  • Low-Cost Speed Controllers
  • Covers a Wide Range of Motors
  • Huge Selection, Six Different Series Offered
  • Printed Circuit Board and Enclosed Styles
  • Over-Current and Under-Voltage Protection
  • Input Ranges: 20 to 50VDC, or 85 to 135VAC
  • Max Power: 750 to 1,500 Watts
  • Peak Current: 15 to 60Amps
  • Low-Cost Speed Controllers
  • Covers a Wide Range of Motors
  • Three Different Series Offered
  • Enclosed Styles
  • Over-Current and Under-Voltage Protection

Helpful Information
Choosing a BLDC Motor Controller
There are very many features on the BLDC Motor Controller but the hardest part is pairing up your BLDC Motor Controller to your brushless dc motor and figuring out if this pair will meet your expectations and get the job done. First you will pick a brushless motor and brushless motor controller, then you will have to check the specifications for each of these and compare to the two to see if they will compatible with each other. You will need to do some research to get the best results. You have to ask yourself what are the main features or options are you looking for in a BLDC motor controller? How much current are you outputting? How much voltage are you inputting? What do I need to control? These are some of the questions you might need or want to ask yourself before you buy a driver/controller that doesnt work with your motor. You need to know all of the motor specifications. What is the rated voltage and speed? How much current can the motor take or output? How much power is it rated for? Etc. Once you figure all of these things out you can now look for a driver/controller with similar or higher ratings. There are many different types of BLDC Motor Controller products made today. Some companies make a BLDC Motor Controller for specific applications there are also companies that make custom a BLDC Motor Controller. What the controller does is directs the rotation of the rotor. In order for the controller to do this, it must somehow detect the location of the rotor. In some cases, encoders or hall effect sensors are used to measure the position of the rotor directly. Another approach is to measure the back EMF, in this case the hall effect sensors are not needed. These types of BLDC Motor Controller are also known as ?sensorless? controllers. Remember much research should be done before buying a motor and brushless dc controller. If you want them to work properly and the way you need it to, research is necessary. I cant emphasize enough. There are many companies all around the world engineering BLDC Motor Controller products to meet your needs for all different types of applications.

How are BLDC Motor Products controlled
Most BLDC Motor Products need a BLDC Motor Controller to run. There are many different types of BLDC Motor Controller products that are manufactured around the world for different applications. Many come with different options and can be custom made. Most are referred to as Electronic Speed Controller (ESC). In a BLDC Motor Controller, either a Hall Effect Sensor or the Back EMF (Electromotive Force) is used to run the motor. The Hall Effect uses three hall sensors within the motor to help detect the position of the rotor. This method is primarily used in speed detection, positioning, current sensing, as well as proximity switching. The magnetic field changes in response to the transducer that varies its output voltage. A feedback is created by directly returning a voltage since 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, in this case, three, 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. The Back EMF, also known as the Counter-Electromotive Force is caused by a changing electromagnetic field. In a BLDC Motor, the 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 and alternating current or pulsating current. At every moment, the polarity of the voltage is the reverse of the input voltage. This method is commonly used to measure the motor's position and speed indirectly.

Applications
BLDC Motor Controller Products are used in a variety of applications in many different industries. Some of the applications are Appliances, Automotive, Aerospace, CNC, Consumer, Instrumentation, Medical, Packaging Equipment, and Semiconductor.

What is a BLDC Motor Controller
A BLDC motor controller (also known as a Driver) is a device that is used to run/control a Brushless Motor. They are also known as Speed Controllers and often referred to as Electronic Speed Control or ESC. Their main purpose is to "drive" the brushless motor, in other words make it run. There are many different types that are manufactured for different applications. The main purpose of a BLDC motor controller is to drive a brushless motor at a speed where a signal is taken that represents that demanded speed. If the speed of the brushless motor is measured, then it is a Feedback speed controller or also known as a closed-loop speed controller. If the speed isn't measured then it is called an open-loop speed controller. A feedback speed controller is more complicated than one that is not, but is much better and more efficient. Brushless motors come in a variety of forms, and the BLDC motor controller output will be different dependent on these forms.

Theory of a BLDC Motor Controller
Theory of a BLDC motor controller The speed of a brushless motor is directly proportional to the supply voltage, so when the supply voltage is reduced, so is the speed, and vice versa. An example is, if your supply voltage is 12 volts and you decrease to 6 volts, then the speed will now run 50% slower than at 12 volts. Now, the question is, how can that be achieved when you have a battery or supply fixed at 12 volts? The BLDC motor controller works by varying the average voltage sent to the motor. It could do this by adjusting the voltage sent to the motor, but this is inefficient to do. A much more efficient way to do this is, to switch the motors supply on and off very quickly. When the switching is fast enough the brushless motor will only recognize the average effect. It will not notice that it is actually being switched on and off. The average speed of the brushless motor increases, as the amount of time that the voltage is on increases compared with the amount of time that it is off. This on-off switching is performed by what is called a power MOSFET (Metal-Oxide-Semiconductor Field Effect Transistor). MOSFETs are devices that can turn very large currents on and off under the control of a low signal level voltage. The time it takes a motor to slow down and speed up depends on the inertia of the rotor, how much torque and friction there is.

History of a BLDC motor controller
From the 1920s-1980s most electrically driven elevators used the Ward Leonard bldc motor controller system. This control system has been used up until the early 21st century. Different variations were implemented into the Ward Leonard system, but were still called by the same name generally. Electrical and mechanical adjustable bldc motor controller units and other new types developed after the Ward Leonard system was introduced. Electron tube types of bldc motor controller units began to develop in the 1920s, but electronic controls didn't begin to displace the Ward Leonard system until thyristor controlled drives were developed in the late 1960s. Ward Leonard's bldc motor controller was rapidly becoming obsolete by the mid 1970s, but replacements for the existing Ward Leonard bldc motor controller has continued until the beginning of the 21st century.

Where is a BLDC motor controller Used
Some applications that use a bldc motor controller are, but not limited to:
  • Appliances
    • Wheel encoders
    • Ice tray and dust box position sensing
    • Door and lid open/close detection
    • Low water indicator
    • Motor current monitoring and AC input current detection
  • Automotive ( High temperature and in cabin)
    • Lighting
    • Wiper systems
    • Airbag deployment systems
    • Brake systems
    • Displays and infotainment
    • Seat belt systems
    • Closure systems
  • LED lighting and Displays
    • Billboards
    • Backlighting (cameras, mobile phones, laptop PC's,etc.)
    • Illumination and signals
  • Office Automation
    • Printers
    • Fax machines
    • Shredder
      Portable
    • Digital Camera
    • Mobile Phone


    How to select a BLDC motor controller
    When selecting a bldc motor controller for your motor, many things should be considered. What is your application? You will need to get specifics about the motor and the bldc motor controller and compare them to see if they are compatible. Once you have figured all this out, you can then begin to compare a different bldc motor controller from different manufacturers.

    Advantages and Disadvantages for a BLDC motor controller
    There are many advantages to using a bldc motor controller . They include the following, but not limited to:

    1.Long lifetime
    2.Efficient
    3.Customizable
    4.Different performance options on one bldc motor controller

    Disadvantages for a BLDC motor controller

    There are far more advantages than disadvantages for a bldc motor controller , but there are a few listed below:

    1.High cost
    2.Complex circuitry
    3.An additional unit to a motor (takes up more space)


    Troubleshooting a BLDC motor controller
    When you are having problems with your bldc motor controller there are multiple things to look for. Different units will have their own way of indicating a problem of fault within the bldc motor controller . Most bldc motor controllers will have a fault light to help indicate a problem that has occurred. Some may have an "alarm" or noise of some sort. Some problems that may occur, but are not limited to are:

    1. Blown phase 2. Improper parts within unit 3. Blown parts within unit 4. Improper wiring/installation (Check user guides for specific hook-up diagrams)

    There is always the possibility that something maybe shorted internally on the board. This is something you might not be able to fix by yourself. Most companies will have a warranty for the product which will allow you to send it back and get it properly fixed and tested.

    How Much do BLDC motor controller Products Cost
    A bldc motor controller comes in all different shapes and sizes. A bldc motor controller can be custom made and ordered from different manufacturers. Although there isn't a certain shape it, most Controllers have a rectangular or square shape to them. They can also come in very small packages as well as very big packages.

    Brushless Motor Controllers consist of, but are not limited to:
    • PCB (Printed Circuit Board)
    • Transistors
    • Capacitors
    • Resistors
    • IC, Chips, microchips
    • Diodes
    • Potentiometers
    • Terminal Blocks/ screw terminals
    • Heat Sinks
    • LEDs
    • LCDs


    Lifetime of a BLDC motor controller
    The lifetime of a bldc motor controller should last you for a very long time, if not forever. That's if, and only if you are running within rated conditions. It is not best to run anything at its limits, that's why there are limits set. If you running your unit within or below rate conditions, you will not have to worry too much about checking in on it. It is always a good idea to check on your bldc motor controller and its conditions. You never know with electronics, they can be unpredictable at times.

    Required Maintenance for a BLDC motor controller
    Occasionally things go wrong with electronics. You should always make sure the environment of your bldc motor controller is within specifications of the unit so that everything will run smoothly and consistently. The temperature, air, dust, and pressure play a big part in electronics. You always want to make sure those allow your bldc motor controller to run and operate properly at all times. Those factors are almost always unpredictable and change all the time.

    Applications
    BLDC Motor Controller Products are used in a variety of applications in many different industries. Some of the applications are Appliances, Automotive, Aerospace, CNC, Consumer, Instrumentation, Medical, Packaging Equipment, and Semiconductor.

    How to select a BLDC Motor Controller
    When selecting a bldc motor controller for your motor, many things should be considered. What is your application? You will need to get specifics about the motor and the bldc motor controller and compare them to see if they are compatible. Once you have figured all this out, you can then begin to compare a different bldc motor controller from different manufacturers.

    Where is a BLDC Motor Controller Used
    Some applications that use a bldc motor controller are, but not limited to:
    • Appliances
      • Wheel encoders
      • Ice tray and dust box position sensing
      • Door and lid open/close detection
      • Low water indicator
      • Motor current monitoring and AC input current detection
    • Automotive ( High temperature and in cabin)
      • Lighting
      • Wiper systems
      • Airbag deployment systems
      • Brake systems
      • Displays and infotainment
      • Seat belt systems
      • Closure systems
    • LED lighting and Displays
      • Billboards
      • Backlighting (cameras, mobile phones, laptop PC's,etc.)
      • Illumination and signals
    • Office Automation
      • Printers
      • Fax machines
      • Shredder
        Portable
      • Digital Camera
      • Mobile Phone


    What is a BLDC Motor Controller
    A BLDC Motor Controller (also known as a Driver) is a device that is used to run/control a Brushless Motor. They are also known as Speed Controllers and often referred to as Electronic Speed Control or ESC. Their main purpose is to "drive" the brushless motor, in other words make it run. There are many different types that are manufactured for different applications. The main purpose of a bldc motor controller is to drive a brushless motor at a speed where a signal is taken that represents that demanded speed. If the speed of the brushless motor is measured, then it is a Feedback speed controller or also known as a closed-loop speed controller. If the speed isn't measured then it is called an open-loop speed controller. A feedback speed controller is more complicated than one that is not, but is much better and more efficient. Brushless motors come in a variety of forms, and the bldc motor controller output will be different dependent on these forms.

© 2011 Anaheim Automation, Inc. - All Rights Reserved