Field Simulation Approach for Computing the Commutation Angle Error of EC Motors

Electronically commutated motors produce a mechanical torque by switching the currents in their stator winding system according to the instantaneous rotor position during rotation. The rotor position is determined by Hall sensors capturing the magnetic field of the rotor's permanent magnets. In operation, the Hall sensors are exposed not only to the rotor field, but also to the field of stator windings. This inevitably leads to a certain commutation angle error (CA error) and a reduced motor performance. This paper presents a general 3-D magnetic field simulation approach for computing the CA error and for finding an optimal position of the Hall sensors. The obtained numerical results and their verification by measurements are presented in detail.