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motor uses
slotless design
The brushless, slotless dc motors from
Xtreme Energy, St. Petersburg, have all the
advantages of slotless, brushless
technology combined with a proprietary
coil winding configuration that reduces
current losses. The motor is also
autoclavable, so it can be used in medical
equipment that needs sterilizing between
uses.
Being brushless, there are no mechanical
contacts between the voltage source and
the motor's rotating components, which reduces maintenance and
potential for failure. It also reduces the electromagnetic and radio
frequency interference (EMI and RFI). The slotless design uses a
basket winding inserted into a ring lamination with no teeth or slots.
Therefore, rotation is smooth with virtually no cogging. The motor
weighs less, has lower magnetic losses, and produces less heat.
Compared to slotted, brushless motors which are 30 to 70% efficient,
Xtreme's are up to 95% efficient. They do not need a cooling fan and
noise levels are low. They are also capable of speeds over 100,000
rpm, while other brushless, slotted dc motors can go no higher than
30,000 rpm. And while costs for other brushless, slotted motors range
from $200 to $2,500, Xtreme's are available for $85 to $850,
depending on size and quantities.
DC Motor Repair
With literally decades of experience, DC
equipment repair has become a specialty at
Jenkins Electric. We service a wide variety of
industrial customers and also provide services
other motor repair centers.
DC motors and generators introduce additional
complexity into the repair process. The additio
of (1) a commutator with brushes, and (2)
rotating armature coils subjected to centrifuga
force are factors not involved in typical AC
repair.
The following procedures and tests are used at Jenkins Electric to ensure top-quality DC machin
repair:
Conductive carbon dust left by worn brushes is cleaned from the armature;
then each commutator is checked for grounds and bar-to-bar shorts with
detailed electrical testing.
Technicians repair most commutator problems in-house. For severely
damaged or non-repairable commutators, we have several excellent
sources for fast delivery of custom manufactured replacements.
Coils are manufactured in-house to assure proper fit. This eliminates
constant bending and shaping during installation which can damage coil
insulation.
Proper banding is critical in DC repair. This ensures that windings are held
in position during high-speed operation.
Field coils are checked using voltage drop testing. Bad fields and interpoles
are rewound in our shop on custom-made forms.
TIG welding is available to eliminate soldered joints where design dictates.
All commutators at Jenkins Electric are turned, undercut, and chamfered
to provide the best possible surface for brush contact.
For corrosive or other severe duty environments, commutator platinum
plating is available to extend wear life.
Neutral setting adjustments are made during final machine testing to
insure proper operation.
A technician installs form coils in the armature with coil leads fitted
to the commutator (left). Coil leads are then soldered or welded int
place.
After multiple dip and bake varnish cycles, the
commutator is turned in a lathe to remove worn
brush tracks and other surface irregularities
A brushless DC motor is an electric motor that operates like a DC motor, but with the roles of the rotor and stator
reversed. The rotor consists of a set of permanent magnets and the stator consists of electromagnets. The motor
has no brushes and no commutator in the traditional sense, but the role of the commutator is played by an
electronic circuit, that switches the current to the different stator coils at the appropriate times. There exist
integrated circuits specially designed for this purpose. Many brushless DC motors contain Hall effect sensors, so
the electronic circuit knows the rotor position and can switch the current in the stator coils accordingly. Some
brushless DC drive circuits use the back EMF in the undriven coils to sense the rotor position, so they do not
need the Hall effect sensors.
The advantages of brushless DC motors over conventional DC motors are high reliability, no production of sparks
and no production of electromagnetic interference. The disadvantage is higher cost due to the complex
electronics.
Brushless DC Motors
There are no sparks, which is one advantage of the bldc motor. The
brushes of a dc motor have several limitations; brush life, brush
residue, maximum speed, and electrical noise. BLDC motors are
potentially cleaner, faster, more efficient, less noisy and more
reliable. However, BLDC motors require electronic control.
Full Step Stepper Motor
This stepper motor is very simplified. The rotor of a real stepper motor
usually has many poles. The animation has only ten poles, however a
real stepper motor might have a hundred. These are formed using a
single magnet mounted inline with the rotor axis and two pole peices
with many teeth. The teeth are stagered to produce many poles. The
stator poles of a real stepper motor also has many teeth. The teeth
are arranged so that the two phases are still 90° out of phase.
This stepper motor uses permanent magnets. Some stepper motors do not have magnets
and instead use the basic principles of a switched reluctance motor. The stator is similar
but the rotor is composed of a iron laminates.
A half-step motor has twice the resolution of a full step motor. It is very popular for this
reason.
The rotor forms a magnetic circuit with the energized stator pole. The
reluctance of a magnetic circuit is the magnetic equivilent to the
resistance of a electric circuit. The reluctance of the magnetic circuit
decreases as the rotor aligns with the stator pole. When the rotor is
inline with the stator the gap between the rotor and stator is very
small. At this point the reluctance is at a minimum. This is where the
name “Switched Reluctance” comes from.