Sensored Versus Sensorless Brushless Motors


There are two types of motors in the market: sensored and sensorless. This article discusses them in detail. 

What is a sensored brushless motor?

It’s a synchronous electric motor that operates on DC or direct current, such as a BLDC motor. They use DC to power unique magnets that revolve around the stator. It comes with sensors that give data to the ESC regarding the rotor position.

What is a sensorless brushless motor?

It refers to a motor without hall sensors. This type of motor is common in various industrial and commercial applications. For example, it can be used in products such as hybrid electric and electric vehicles to usual household electric tools.

These motors are more advanced technologically than brushed DC motors. As a result, their integration into products can offer greater efficiency than their counterparts. So, if your company has not made a move, it’s time to upgrade and contract an electric motor company in India

Let’s understand how these motors work:

How do sensored vs sensorless brushless motors operate?

A brushless motor gets power from the electronic speed control (ESC). The ESC must know the rotor’s position to rev the motor from zero RPM swiftly. When it does not know the rotor’s position, the ESC has to decide it. The ESC determines the position by delivering power to the motor and getting electromotive force (EMF). It means there’s the production of a voltage signal that is sent back to ESC as the rotor moves. The feedback loop allows the ESC to know the position of the rotor.

Between sensored or sensorless motors, which is better?

First, sensorless motors need close monitoring by a controller to keep the engines speed in check. In these motors, the controller has to use the back EMF to maintain the speed of the rotor at a reasonably safe level.

However, you can argue that the sensorless is a better alternative as they have fewer parts that can be damaged. So, they become less costly as fewer replacements and repairs occur.

Electric motor companies in India recommend sensorless motors as the best option in terms of speed. In addition, because they have fewer parts prone to damage, they are suitable for operation in harsh conditions.

Therefore, what are the cons of these two types of motors?

Pros of sensored brushless motors.

Here are a few advantages of getting a sensored brushless motor.

  • They can accelerate swiftly and firmly from zero RPM.
  • They produce more torque at slow speed than their counterparts
  • They allow the motor to operate safely by monitoring its condition.

Pros of sensorless brushless motors

  • Their performance is excellent at high speed
  • Its ESC can alter the power timing sequence sent to the motor winding.
  • They are lighter in weight than sensored motors
  • They are less complicated
  • Less susceptible to failure

Primary Applications. 

Sensored motors are great if your application needs low-speed torque around zero RPM. Applications that need low-speed torque are RC car based. They include Rock Crawling or any other kind of slow RC Car action. It’s also convenient in high-gearing vehicles that need a lot of power torque to start. 

When a motor requests to accelerate faster from a stop, great power is drawn. So, smooth acceleration is impossible if the motor is not in sync with ESC reliability or faster. So, a sensored motor, in this case, comes in handy. Other applications include RC boats, airplanes and helicopters. Most operations in this application require high speed.

Applications of sensorless motors

These motors are used in various devices such as CD and DVD players to computer hard drives. It’s also used in a cooling fan or electric bicycle. This motor does not require warm-up to start to ensure the rotor is in position. What they lack in start-up torque is compensated with power and affordability. They are essential in many applications that need utmost efficiency and reliability. For example, HVAC systems heat and cool homes, commercial spaces, and home refrigeration.

The bottom line is that both motors are good in their respective way. Productivity depends on their application. Although they have some differences, they offer similar functions.

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