Influence of the Placement Accuracy of the Brushless DC Motor Hall Sensor on Inverter Transistor Losses

Low-power BLDC motors are often and willingly used in many drive devices due to their functional advantages. They are also used in advanced positioning systems, where their good dynamic performance parameters are used. The control systems use shaft position sensors mounted on motors, the structure of which is based on magnetic elements and Hall sensors. The aim of this article was to investigate the influence of the BLDC motor quality on the correct operation of the control semiconductor system. The article presents the effect of BLDC motor shaft observation system’s inaccuracies on the friction and current amplitudes of individual inverter keys. Waveforms of the controller phase currents are considered and recorded on a test bench that allows precise sensor position changes. In addition, the effect of sensor misalignment on power losses in individual inverter transistors is investigated. The article shows a significant influence of the motor shaft observation system’s assembly accuracy on the current amplitudes of individual driver transistors and their power losses, which makes it necessary to consider these parameters when constructing power electronic systems.