Torque Ripple and Vibration Reduction in BLDC Motors Using a Bilayer Stator Structure

Résumé fourni par la source

Brushless DC (BLDC) motors are widely used in electric mobility, robotics, and compact actuation systems because of their high efficiency and torque density; however, commutation-induced torque ripple remains a significant practical limitation. Torque ripple excites mechanical vibration, increases acoustic noise, and accelerates wear in bearings and transmission components. This article proposes a bilayer stator BLDC motor architecture in which an auxiliary stator with a controlled mechanical phase shift is excited using delayed pulses to compensate for torque deficits during main-stator commutation. The proposed structure is investigated using finite-element simulations and validated experimentally using prototype motors fabricated from commercial outrunner motor components. Results show that the proposed configuration reduces torque ripple by up to 74% and decreases total current consumption by up to 25% under comparable operating conditions. These results demonstrate that the proposed architecture provides a practical approach for achieving smoother torque production, reduced vibration, and improved efficiency in BLDC drives using commercially available hardware.

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