In today’s rapidly advancing motor technology, the sensored motor has become the preferred choice in fields such as industrial automation, robotics, and new energy vehicles. Compared to sensorless motors, the biggest feature of sensored motors is the built-in position sensor, which provides real-time rotor position feedback to achieve precise speed and torque control. This article will analyze the internal structure and working principle of sensored motors in detail, highlighting their core advantages.
Internal Structure of Sensored Motors
The internal structure of a sensored motor mainly consists of the following key components:
Stator
The stator is usually made of laminated silicon steel sheets and wound with motor coils. Its role is to generate a rotating magnetic field by energizing the windings, which drives the rotor.
Rotor
The rotor is the core rotating part of the motor, often constructed with permanent magnets. By interacting with the stator’s rotating magnetic field, the rotor converts electrical energy into mechanical energy.
Position Sensor
This is the defining component of a sensored motor compared to a sensorless motor. Common sensor types include Hall sensors, encoders, and resolvers. These sensors detect the rotor angle and position in real time, sending accurate feedback signals to the driver.
Driver Circuit
The driver circuit adjusts the switching sequence of the three-phase current based on sensor feedback and control commands, ensuring the motor runs according to the target speed and direction.
With these structural elements, sensored motors deliver higher control accuracy and operational reliability, making them an ideal hardware foundation for demanding applications.
Working Principle of Sensored Motors
The working mechanism of a sensored motor can be summarized into three steps: magnetic field interaction, position feedback, and precise driving.
Magnetic Field Interaction
When the stator windings are energized, they produce a rotating magnetic field. The permanent magnets on the rotor interact with this field, causing the rotor to rotate. The motor’s rotational speed is directly linked to the frequency of the input current.
Position Feedback
As the rotor turns, the position sensor continuously detects the rotor’s angle and sends this data to the driver. This process effectively gives the motor “eyes,” enabling it to sense its exact position.
Precise Driving
Based on the feedback signals and control strategy, the driver dynamically adjusts the phase and amplitude of the current. This ensures smooth operation and precise speed control, even under low-speed or high-load conditions.
This closed-loop control mechanism allows sensored motors to deliver high torque at low speeds, smooth startup, and excellent dynamic performance.
Advantages and Applications of Sensored Motors
Thanks to the addition of sensors and feedback mechanisms, sensored motors offer unique advantages:
Superior low-speed performance: Stable operation even at very low speeds, suitable for precision equipment.
Smooth startup: Eliminates jitter and missteps common in sensorless motors.
Accurate control: Closed-loop speed and torque regulation meets high-precision requirements.
Wide applications: Extensively used in robotics, CNC machines, medical equipment, and electric vehicle drive systems.
Conclusion
In conclusion, sensored motors stand out with their unique internal structure and advanced working principle, providing a reliable solution for modern industry and intelligent applications. The integration of position sensors grants the motor precise self-sensing and feedback ability, greatly improving operational stability and control flexibility. With the rapid growth of smart manufacturing and electric vehicle industries, sensored motors are expected to play an increasingly critical role across multiple sectors.