BLDC Motor Upgrade

In my recent project, I added Hall sensors to a brushless DC (BLDC) motor because the new motor controller I switched to required the presence of Hall sensors. Hall sensors are essential in BLDC motors as they provide precise rotor position feedback, enabling the controller to efficiently manage the commutation sequence. This precise control is crucial for optimizing the motor's performance, ensuring smooth operation, and preventing potential issues such as stalling or inefficient power use. Additionally, Hall sensors enhance the motor's reliability and responsiveness, making it ideal for applications where precise motor control and efficiency are paramount.

Motor

The motor to be upgraded is 1000W, 60 Volts BLDC motor used for small electric vehicles. As shown in the image it supports normal wheels and has disk brakes.

Hall Effect Sensor

A Hall effect sensor is a transducer that varies its output voltage in response to changes in the magnetic field. It operates based on the Hall effect, which occurs when a magnetic field perpendicular to an electric current passing through a conductor produces a voltage difference across the conductor, perpendicular to both the current and the magnetic field.

Here's a breakdown of how a Hall effect sensor works:

Electric Current Flow: An electric current is passed through a thin strip of conductive material.
Magnetic Field Interaction: When a magnetic field is applied perpendicular to the direction of the current, the charge carriers (electrons or holes) in the conductor experience a force due to the Lorentz effect, causing them to accumulate on one side of the conductor.
Voltage Difference: This accumulation of charge carriers creates a voltage difference across the conductor, perpendicular to both the current and the magnetic field. This voltage difference is known as the Hall voltage.
Sensor Output: The Hall voltage is measured and used as an output signal. The magnitude of the Hall voltage is directly proportional to the strength of the magnetic field.

Step 1: Remove all the epoxy

First, all the epoxy needs to be removed to expose the hole where the cables get inside the motor.

Before removing the epoxy

After removing the epoxy

Missing Hall sensors.

Step 2: Rewire 5 extra cables

5 new cables need to be wire through the axis of the motor, this cables provide power to the hall sensors and transmit the data from the sensors back to the motor controller.