International Journal of Scientific Research and Engineering Development-– Volume 2 Issue 4, July – Aug 2019 Available at www.ijsred.com ISSN : 2581-7175 ©IJSRED: All Rights are Reserved Page 722 Design and Development of a Brushless Direct Current Motor Chandan Das 1 , Md. Barkat Ullah 2 , M. Asaduzzaman 2 , Syeed Ashraf 3 , Humayun Kabir 1 , Md. Abdul Mannan Chwdhury 1 1 Department of Physics, Jahangirnagar University, Savar, Dhaka-1342, Bangladesh. 2 Dept. of Physics, Bangladesh Army University of Engineering & Technology , Qadirabad Cantonment, Natore, Bangladesh. 3 Bangladesh School Sohar, Sohar, Oman. Abstract: The objective of the present work is to design and develop a brushless dc motor (BLDC).With the knowledge acquired from various magnetic designs and its power a motor has been built. The primary goal and focus is to be able to make a fully functioning motor. Once it is determined what type of material is to make the stator and other portions of the motor out of a reasonable size and power output is estimated. Using a general radial flux motor concept, the design is refined through calculations while keeping in mind the limitations of machining. This proved to be very difficult given the type of material that should to be machined. After many checks and calculations the final design was approved and parts was ordered. Using this radial flux motor design, all parts are manufactured using various machines; lathes, end mails, band saws, CNC mills, etc. from one single piece of bar stock steel. To power the designs stellaries, Texas Instrument, one phase BLDC motor controller is used. The motor has been modified to accommodate the Hall Effect sensors necessary to operate the controller. As will be shown throughout the research, many difficulties and frustrations are encountered during design and machining of the motor. It will be thoroughly explained through this research that the theories and practices in both magnetic design and electrical circuit theory can be manipulated into a device that changes electrical energy into mechanical energy. Keywords: BLDC motor, Stator, Rotor, Hall sensor, Low Voltage Power Supply. I. Introduction The concept behind converting electrical energy into mechanical energy has been known since the late 1820’s when the first electric motor was successfully tested. These concepts over the years have been improved upon, but for the most part have remained the same. This applies to design of electric motors. Over the years there have been many upon many design changes to improve efficiency and output power, however the theories motor used today these basic and fundamental magnetic and electrical properties hold constant and are demonstrated through this research. Electric motors are everywhere in world today. The world as we know it exists because of the electric motor. From the Hoover dam to our laptop computer there is an electric motor serving a purpose. From the beginning, motors have been used to improve the everyday life of the people on the Earth. They generate thousands upon thousands of kilowatts of electricity of power homes, factories, televisions, computers, microwaves, etc. They allow for one man to move thousands of pounds of material from one place to another replacing the need for twenty men to do the same job, just by using a simple hydraulic system with a motor. In today’s world electric motors power cars that can go from zero to sixty miles/hour in no more than a few seconds. Motors are essential to today’s way of life and make life easier as we know it. As of today there are over 15 types of various DC and AC motors that all serve the purpose of converting electrical energy into mechanical energy or vice versa[1]. Of these many different one design in particular was chosen for this research. It displays the basic magnetic and electrical principles as mentioned earlier and is composed of a design that fits the overall goal this research. The brushless direct current (BLDC) permanent magnet motor was chosen to demonstrate the theories and practices behinds electric motors. These particular types of motors are known for their high durability due to simplicity in design, and high RPM capabilities. BLDC motors have both small and large applications. For example, in every computer there is a hard drive. A hard drive consists of spinning disk that is powered by a small BLDC motor to rotate the hard drive disks at very fast speeds [2]. On the other hand with the newly developed hybrid cars coming out along with a small fuel efficient engine there are typically two or even four BLDC motors located on either the axel or each individual wheel [3]. Both of these motors are similar to this design in that they both run off of permanent magnets. This particular design is in between these two extreme (small, large) types of motors. The design although simple has been made extremely difficult when all aspects of a motor were to be taken into account and designed from scratch. The goal is a twelve volt, quarter horsepower design. RESEARCH ARTICLE OPEN ACCESS