Navigating the Challenges of Motor Commutation

In the world of motion control, engineers often face the challenge of integrating different brands of drives and motors into a cohesive system. At first glance, mixing and matching equipment might not seem like a problem, especially if the sizes of the components line up. However, one critical factor can make or break the success of this integration: motor commutation. Understanding this concept is key to ensuring that drives and motors work together efficiently, but many engineers and operators may struggle to fully grasp its significance.

Motor commutation involves the process of switching between motor phases to ensure smooth, continuous operation. While the term might sound abstract, its impact on performance is very real. In this article, we’ll dive into the importance of commutation, explain how it works, and discuss the challenges faced when trying to pair different motors and drives, especially across brands.

What is Motor Commutation?

Brushed motor commutation for a single pole of a motor. (Image: Valin Corporation)

To understand motor commutation, it’s essential to recognize that the goal is to maintain a 90-degree angle between the rotor’s magnetic field and the motor’s stator field. This alignment is crucial because it ensures that the motor generates torque as efficiently as it can. Greater deviation between these two fields directs more energy off the desired path, reducing torque and overall efficiency.

One way to explain commutation to someone unfamiliar with engineering is by comparing it to riding a bicycle. When you first hop on a bike, the pedals may not be at an optimal angle. You instinctively adjust the force applied to the pedals, deciding which foot to push, how hard to push, or whether to pull up with one foot while pushing down with the other. If the pedals don’t move as expected, it might be because they’re at the wrong angle, or you’re not applying enough force. This is similar to the commutation process in motors, where the motor’s electrical phases must be carefully synchronized to maintain consistent movement and efficiency.

In more technical terms, motor commutation involves switching the current through the motor’s windings in such a way that the rotor continues rotating smoothly. In a brushed DC motor, commutation occurs when brushes switch between contacts, reversing the direction of current as the rotor turns. This process is relatively straightforward, but it becomes more complex in brushless motors.

Brushless Motor Commutation

In a brushless DC motor, commutation is achieved electronically using a sensor or controller to determine the rotor’s position. Without brushes to physically change the current flow, brushless motors rely on sensors to adjust the current, ensuring that the rotor remains aligned with the stator’s magnetic field.

The A and B channels of an incremental encoder. (Image: Valin Corporation)

One common method of motor commutation is through a Hall Effect sensor. This sensor detects the presence of a magnetic field and converts it into a voltage signal, which can be used to determine the rotor’s position. The sensor feedback allows the drive to adjust the current and phase switching accordingly, keeping the motor running smoothly.

Another method is using either a resolver or an encoder directly attached to the shaft. Resolvers are analog feedback devices using sine and cosine waves that change as the rotor turns. Corresponding readouts indicate an absolute position within a full revolution of the motor. Encoders are digital feedback devices with a wide variety of protocols. Absolute encoders retain position data without power within at least one full motor revolution. Incremental encoders report relative position instead of absolute position and do not retain position data after power loss.

One electrical cycle, which is typically one motor revolution, of a resolver. (Image: Valin Corportation)

None of these methods detect the magnetic field like the Hall Effect sensors do. Incremental encoders usually include simulated Hall Effect signals while the other methods don’t need them because they report absolute positions. Either way, these methods need to be aligned to the rotor so that their absolute positions or Hall Effect simulations correctly report the magnetic field location to the controls.

Yet another method that is more sophisticated and not as widely used has a number of different names including Wake ‘n’ Wiggle and sensorless commutation. These methods rely on making small movements of the motor on start-up and sensing to figure out where it is before making any motion. This is like moving the bike pedals to a known location before getting on the bike.

The Importance of Proper Commutation

Understanding commutation is essential for achieving peak motor performance. If commutation is misaligned or neglected, inefficiencies arise, which can manifest as wasted energy, excessive heat, or poor motor performance. For engineers working with motion-controlled applications, optimizing commutation is crucial to maximizing torque output and reducing waste.

In some applications, where high efficiency is less critical, simple electronics may be used to allow for more relaxed commutation tolerances. These systems may not focus on minimizing torque loss and can operate with greater flexibility, especially when precision isn’t as important. However, for systems where efficiency is paramount, proper commutation becomes an unavoidable priority.

Problems in the Field

What can really make commutation problems frustrating is that they can be difficult to identify as commutation problems. Many systemic problems mean the system either works or it doesn’t with very little in-between “it sort of works” scenarios. Commutation problems come with several “it sort of works” scenarios that a less-experienced person won’t understand as being related to commutation.

A servo motor that gets too hot is typically correctly diagnosed as being under-sized. However, if the commutation angle is incorrect, but still within 90 degrees, then the motor will still run, but so inefficiently that it has to work harder with the result being that it seems under-sized and gets too hot.

Another frustrating scenario is when the motor sometimes works on start-up but doesn’t at other times. This leads people down all sorts of wrong troubleshooting paths such as cables, temperatures, positions, sensors, etc. This can happen though when using Hall Effects or simulated Hall Effect signals with incremental encoders. Other technologies have become more common, but these are still used and there is a large existing installed base.

When using three Hall signals, there are six different states that the drive may see on start-up. If Halls 1, 2, and 3 are wired in the wrong order, the drive may see two correct states and four incorrect ones. When the drive starts up with a correct state, it works. However, two-thirds of the time it starts up with a wrong state and doesn’t work. To further complicate matters, when it doesn’t work, this can be an instant fault, an uncontrolled jump, or simply inefficient motion that results in a hot motor. Getting different results each time can be very frustrating and time-consuming.

The Challenges of Mixing and Matching Motors and Drives

The main challenge of mixing and matching drives and motors from different brands lies in ensuring that the commutation is correctly set up. Each motor and drive combination requires specific configurations, including details like commutation angles and the relationship between the rotor’s position and the stator’s windings. Without this precise information, even the best motor may fail to operate optimally.

For engineers who are experienced with one particular brand or type of motor, this task may be straightforward. However, when working with different manufacturers or unfamiliar equipment, achieving proper commutation can be a tricky and time-consuming process.

In conclusion, understanding and implementing proper motor commutation is essential for ensuring that drives and motors function together efficiently in all motion-controlled applications. Whether using resolvers, Hall Effect sensors, or alternative methods like “Wake n Wiggle,” the goal is to achieve the most efficient torque output possible while minimizing wasted energy. As engineers continue to integrate components from different manufacturers, maintaining proper commutation settings will remain a critical step in achieving optimal system performance.

By balancing efficiency with economic considerations, engineers can navigate the challenges of commutation and create systems that meet the performance demands of various applications.

This article was written by Corey Foster, Director of Automation Sales and Application Engineering, and Bruce Ng, Applications Engineer – Automation Products, both at Valin Corporation (San Jose, CA). For more information, visit here .