Introduction

Sensored motors are a cool step up in motor technology, giving us way better control and performance for all kinds of uses. What sets them apart from sensorless motors is the built-in sensors that keep track of the rotor’s position in real-time.

This means the motor controller can make really precise adjustments, making the motor run smoother, more efficiently, and with more power at low speeds. This makes sensored motors perfect for things where you need everything to work just right, like in robots, electric cars, and factory machines.

Thanks to the sensors, engineers can tweak motor performance, cut down on wear and tear, and make the motor last longer. That’s why sensored motors are the go-to choice for high-performance and demanding jobs.

Components of a Sensored Motor

• Rotor: The part that spins, usually with magnets or electromagnets.
• Stator: The part that stays still, with coils that create a magnetic field to move the rotor.
• Power Supply: Provides the electrical energy needed for the motor.
• Motor Controller: An electronic unit that uses the sensor info to manage the motor’s power.
• Hall Effect Sensors: Tiny devices inside the motor that detect the rotor’s position by sensing the magnetic field.
• Commutation Circuit: Part of the motor controller that switches the current in the motor’s coils to keep the rotor spinning.

Working Principle of a Sensored Motor

Sensored motors are marvels of modern engineering, utilizing advanced sensor technology to achieve precise control and optimal performance. Here’s a detailed breakdown of how they work:

1. 1. Sensing the Rotor: At the heart of a sensored motor are specialized sensors, often called Hall Effect sensors. These sensors are strategically placed within the motor assembly to detect the position of the rotor—the rotating part of the motor. When the motor is activated, these sensors spring into action, quickly determining the exact location of the rotor.

   2. Sending Signals: Once the sensors have pinpointed the rotor’s position, they relay this critical information to the motor controller in real-time. This communication is crucial, as it allows the controller to stay informed about the rotor’s whereabouts throughout the motor’s operation.

   3. Timing is Key: Armed with the rotor’s position data, the motor controller orchestrates precise timing for the switching of current in the motor’s coils. This timing is essential for maintaining synchronization between the magnetic fields generated by the stator (the stationary part of the motor) and the rotor. By adjusting the current flow at just the right moment, the controller ensures that the magnetic fields remain aligned, facilitating smooth and efficient operation.

   4. Continuous Adjustment: As the rotor continues to rotate, the sensors continue to feed real-time updates to the motor controller. This ongoing feedback loop allows the controller to make continuous adjustments to the power and timing supplied to the coils. By dynamically adapting to changes in rotor position, speed, and load, the controller optimizes the motor’s performance for maximum efficiency and reliability.

   5. Smooth Operation: The precise control afforded by sensored technology translates into exceptionally smooth motor operation. Whether starting up from a standstill or operating at low speeds, sensored motors exhibit minimal jerking or vibration, resulting in a smoother and more enjoyable user experience.

   6. Feedback Loop: The relationship between the sensors and the motor controller is symbiotic, forming a continuous feedback loop. The sensors continuously update the controller with real-time data on rotor position, while the controller adjusts motor operation accordingly. This seamless exchange of information ensures that the motor operates with precision and consistency under varying conditions.

Thanks to this setup, sensored motors are super precise and efficient, making them great for jobs where you need things to work just right, like in robots, electric cars, and industrial machines.

Types of Sensors

Sensored motors use different kinds of sensors to keep things running smoothly and precisely. Here are some of the common ones:

1. Hall Effect Sensors

• What They Do: Detect the rotor’s position by sensing magnetic fields.
• Where You’ll Find Them: Mostly in brushless DC (BLDC) motors.
• Why They’re Great: They’re reliable, cheap, and can work in many environments.

2. Optical Encoders

• What They Do: Use light to figure out the rotor’s position and speed.
• Where You’ll Find Them: High-precision stuff like robots and CNC machines.
• Why They’re Great: They offer high resolution and accuracy.

3. Resolvers

• What They Do: Convert the rotor’s position into electrical signals.
• Where You’ll Find Them: Tough environments and places needing high reliability, like aerospace and industrial machinery.
• Why They’re Great: Super accurate and can handle noise and extreme conditions.

4. Magnetic Encoders

• What They Do: Use magnetic fields to determine rotor position.
• Where You’ll Find Them: Dusty, dirty places where other sensors might fail.
• Why They’re Great: They’re durable and can handle rough conditions.

5. Inductive Sensors

• What They Do: Use electromagnetic induction to sense the rotor’s position.
• Where You’ll Find Them: Automotive and industrial applications.
• Why They’re Great: No-contact measurement and resistant to environmental factors.

6. Potentiometers

• What They Do: Measure the rotor’s position with a variable resistor.
• Where You’ll Find Them: Simpler applications that don’t need extreme precision.
• Why They’re Great: They’re simple and cost-effective.

Advantages of Sensored Motors

• Precise Control: Hall Effect sensors give you pinpoint accuracy on the rotor’s position, making the motor’s operation super precise.
• Efficient Performance: Keeps things running efficiently by optimizing power and timing, saving on energy.
• High Torque: Packs a punch at low speeds, perfect for when you need that extra start-up power.
• Improved Responsiveness: Quickly adapts to changes in load or speed, so your motor performs better overall.
• Better Heat Management: Stays cooler, which means the motor lasts longer.
• Enhanced Safety: Accurate monitoring and control help prevent problems, making the system safer.

With these advantages sensored motors can be used in wide ranger of applications like EVs, Robotics, Drones, Industrial Machinery, Home Appliances, Power Tools, Elevators and Escalators, Electric Bikes and Scooters, Wind Turbines, Medical Devices and many more.

Maintenance of Sensored Motors

Taking care of your sensored motor is key to keeping it running smoothly for the long haul. Here’s what you need to do:

• Regular Inspections: Periodically check the motor and sensors for wear, damage, or loose connections.
• Cleanliness: Keep the motor area clean using compressed air or a soft brush to remove dust and debris.
• Lubrication: Lubricate moving parts according to the manufacturer’s guidelines to reduce friction and wear.
• Cooling System: Ensure cooling fans and vents are clear to prevent overheating.
• Sensor Check: Regularly verify the alignment and functionality of the Hall Effect sensors.
• Firmware Updates: Check for and install firmware updates from the manufacturer to improve performance.
• Electrical Connections: Inspect and tighten all electrical connections to avoid erratic performance and damage.