Electronic – Running a brushless DC motor on low rpm using servo tester

brushless-dc-motordiy

Background

I'm working on a gift for the wife for Christmas – an electric bobbin winder (a winding machine/spooling machine) – which will work in the same way as this machine:

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It winds yarn on spools, and you control the rotational speed using a pedal. My idea for the motor and control setup is as follows:

  • Brushless motor for durability and low noise
  • Brushless motor is connected to an ESC (electronic speed controller)
  • Electronic speed controller is connected to power supply AND an analog servo tester
  • I utilize the potentiometer on the servo tester, for speed control of the brushless motor.

The motor will have to run smoothly on low RPMs ( < 15 rpm) as well as high RPMs (~5000 rpm).

Questions:

  1. What should be the specs on the motor – will more poles be better? (i.e. 24n22p is better than 14n12p?) Should it be sensored?
  2. Will a setup as described, using a servo tester, be able to run the motor on low RPMs ( <15 rpm)? Or do low-RPM running of motor require different type of controller unit? (i.e. arduino, raspberry pi, …)

Best Answer

For 15 RPM you want as many poles as possible and sensored. More poles results in smoother operation at low RPM, and sensorless is only reliable for applications with zero startup torque and high running speeds. Even with sensored, I suspect you may have issues with radio controlled equipment since 15 RPM is pretty damn slow. I would run it by some RC truck guys first to see if they think smooth reliable operation is possible at 15RPM. The airplane guys won't be of help since they don't use sensored since it's more expensive and propellers are low starting torque, high RPM applications.

More poles can limit speed at higher RPM since the ESC must commutate much more frequently and faster per RPM, but it shouldn't be an issue at 5000RPM.

You may have resolution issues with a servo tester since the knob will be able to go from 0 to 100% with the maximum RPM probably being in the thousands of RPM. I'm not even sure if a RC ESC has enough pulse width input resolution to reliably read and operate 15 RPM.

I would consider gearing to better accommodate the low RPM side but that makes cost spike considerably. You are probably going to run into torque issues at 15RPM without gearing even if it does rotate smoothly and reliably.