sensoredBLDC

SensoredBLDC refers to a brushless DC motor that uses one or more position sensors to provide real-time rotor position information to the motor controller. This information enables precise electronic commutation and speed control. In a typical three-phase sensored BLDC, position sensors are often Hall effect sensors arranged around the stator to generate digital signals corresponding to rotor teeth passing by, usually at fixed electrical angles.

The most common arrangement uses three Hall sensors, combined with the known winding sequence, to determine the rotor’s electrical position and speed. The controller uses these signals to trigger commutation in a six-step (trapezoidal) sequence or, with suitable control strategies, to implement more sinusoidal-current control. Sensor signals allow immediate starting torque and smooth low-speed operation, reducing torque ripple and improving control accuracy at low and zero speeds.

Common alternative sensors include resolvers and optical encoders, which can offer higher resolution or robustness in harsh environments, but Hall sensors remain the predominant choice for many BLDC applications due to simplicity and cost.

Compared with sensorless BLDC motors, sensored variants provide reliable start-up and low-speed performance, at the expense of additional components, wiring, and potential sensor failure points. They are widely used in robotics, automated machinery, electric vehicles, drones, and consumer and industrial motor drives where precise rotor position feedback is advantageous.

Key design considerations include sensor accuracy and reliability, wiring integrity, temperature effects on sensors, and the integration of sensor signals with the motor controller’s commutation logic.