This innovation in BLDC motor control uses refined Hall sensor feedback to generate virtual sensing data, optimizing control performance from low to high speeds. Integrated into the ESCON2 speed controller range, the new BLDC motor control technique redefines how brushless DC motors are managed in compact and embedded applications.
Hall Sensor-Based Virtual Feedback
The new control method analyses the switching edge distribution of a motor’s Hall sensors during initial revolutions. This approach compensates for the low resolution and inconsistencies in Hall sensor signals, generating precise virtual sensor data that improves speed stability—even at low RPMs (from just 300rpm)—comparable to encoder-based systems.
Superior Performance Without an Encoder
maxon’s testing shows that ESCON2 controllers using Hall sensor feedback achieve smoother control than typical servo controllers with encoders. This not only enhances energy efficiency but also eliminates the need for costly encoders—cutting the application’s footprint and simplifying setup.
Field-Oriented Control for Maximum Efficiency
The ESCON2’s field-oriented control (FOC) system regulates both the magnitude and angle of the stator’s magnetic field, ensuring sinusoidal motor currents across the full speed range up to 120,000 rpm. With 10 kHz speed control and 50 kHz current control rates, the system enables precise acceleration and motion profile execution for demanding applications.
Compact and Scalable Hardware Options
ESCON2 is available in multiple formats, including:
- Nano (23 × 16 × 4.5 mm, 2.5g) for ultra-compact applications
- Micro and Module PCB-based formats for embedded integration
- Ready-to-connect housed controllers for cabinet or close-to-motor installation
These formats support 2A to 30A continuous current outputs, making them suitable for a wide range of motor control tasks.
Seamless Integration and Setup
To streamline development and integration, ESCON2 offers:
- Digital and analog I/Os
- USB, RS232, and CAN interfaces (CiA402)
- Configuration via maxon’s Motion Studio with Startup and Regulation Tuning wizards
This allows engineers to get up and running quickly while fine-tuning control parameters with minimal effort.
