{"id":416004,"date":"2009-06-29T16:57:00","date_gmt":"2009-06-29T16:57:00","guid":{"rendered":"http:\/\/www.electronicsweekly.com\/news\/design\/power\/dyson-vacuums-104000rpm-brushless-dc-technology-2009-06\/"},"modified":"2025-07-02T10:52:19","modified_gmt":"2025-07-02T09:52:19","slug":"dyson-vacuums-104000rpm-brushless-dc-technology","status":"publish","type":"post","link":"https:\/\/www.electronicsweekly.com\/market-sectors\/power\/dyson-vacuums-104000rpm-brushless-dc-technology-2009-06\/","title":{"rendered":"Dyson vacuums 104,000rpm brushless DC technology"},"content":{"rendered":"<p><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/static.electronicsweekly.com\/news\/wp-content\/uploads\/sites\/16\/2009\/06\/itemid-53137-getasset.jpg\" alt=\"itemid-53137-getasset.jpg\" width=\"168\" height=\"128\" \/><\/p>\n<p><strong><a rel=\"image\" title=\"Dyson\" href=\"http:\/\/www.dyson.co.uk\/\" rel=\"nofollow\" target=\"_blank\"><strong>Dyson<\/strong><\/a><\/strong> has developed gone to 104,000rpm brushless DC technology to combine efficiency and manufacturability in its latest handheld vacuum cleaner. <\/p><div class=\"elect-content\" style=\"margin-left: auto; margin-right: auto; text-align: center; \" id=\"elect-50744761\"><div id=\"x02\">\r\n<script type=\"text\/javascript\"> if ($(window).width() <= 768) { googletag.display('x02'); } <\/script>\r\n<\/div>\r\n<\/div>\n<p>&#8220;Because it is two pole, it is very simple, and when you make it run at high speed, you can make it incredibly small,&#8221; Dyson&#8217;s Andy Clothier told <em>Electronics Weekly<\/em>. &#8220;It is 84% efficient, which is high at this small size. At this voltage and power level, to get a brushed motor this efficient is very difficult. Our old motor was 40% efficient.&#8221; <\/p><div class=\"elect-test\" style=\"margin-left: auto; margin-right: auto; text-align: center; \" id=\"elect-241424420\"><div id=\"DFP-EW-InRead1\">\r\n<script type=\"text\/javascript\"> if ($(window).width() > 768) { googletag.display('DFP-EW-InRead1'); } <\/script>\r\n<\/div>\r\n<BR>\r\n<\/div>\n<p>Overall the motor, dubbed DDM (Dyson digital motor) V2, is 55.8mm in diameter and weighs 139g. <\/p><div class=\"elect-post-content-2\" style=\"margin-left: auto; margin-right: auto; text-align: center; \" id=\"elect-374629697\"><div id=\"DFP-EW-InRead1-Mobile\">\r\n<script type=\"text\/javascript\"> if ($(window).width() <= 768) { googletag.display('DFP-EW-InRead1-Mobile'); } <\/script>\r\n<\/div>\r\n<\/div>\n<p>Notoriously tricky to start predictably, the motor uses asymmetric poles. &#8220;You have to have enough saliency on the poles to make it start in the right direction,&#8221; said Clothier. <\/p>\n<p>With brushless motors, there is a choice: sensored or sensorless &#8211; incorporate a magnetic sensor have tell the electronics when to switch coil polarity, or use a more powerful processor and sense rotor position from back-EMF. <\/p>\n<p>&#8220;The way we designed it was to integrate the electronics into the motor. It is the least expensive way of doing it,&#8221; said Clothier. &#8220;The PCB is in exactly the right place to carry a Hall sensor.&#8221; <\/p>\n<p>Control comes from a simple 8-bit Microchip microcontroller, not one that has special motor control peripherals, said Clothier: &#8220;We used our own motor control technology. To get the absolute best, we make sure the motor produces constant power regardless of speed and the battery voltage.&#8221; <\/p>\n<p>The power control is largely open loop &#8211; determined from detailed knowledge of the motor and impeller dynamics, combined with motor speed derived from the Hall sensor. Up to 3,300 adjustment per second are made. <\/p>\n<p>The battery is either six or four lithium ion cells depending on the vacuum cleaner model: DC31 (pictured)\u00a0or DC30 respectively. <\/p>\n<p>Up to 10A at 20V, and up to 13A when the battery voltage drops, is switched into the motor by an H-bridge of mosfets. <\/p>\n<p>To get current to change direction fast enough with such a low supply voltage requires low-inductance windings &#8211; in this case twin coils wound in parallel. <\/p>\n<p>The whole motor, and its mechanical and air environment, was modelled extensively. <\/p>\n<p>&#8220;That is where most of the work went in: we developed our own simulation tools to model the whole motor including its electronics,&#8221; said Clothier. &#8220;We also used some commercial finite element software for spot checks and detailed work, but 90% was designed by our own software.&#8221; <\/p>\n<p>Modelling, for example, showed the sintered neodymium permanent magnet rotor was small enough not need a carbon fibre sleeve to stop it flying apart at full speed. <\/p>\n<p>&#8220;This is the kind of thing that looks simple and needs a lot of work,&#8221; Mathew Childe told <em>Electronics Weekly<\/em>. &#8220;We modelled the motor dynamics and made sure it was stable against vibration right up through its acceleration range, checked the acoustic noise and checked the resonances.&#8221; <\/p>\n<p>The team also built prototypes that were tested using accelerometers and laser displacement instruments, then fed-back the results. &#8220;All the way through, you learn to improve and adapt the modelling process,&#8221; said Childe. <\/p>\n<p>High rotational speed put means the impeller can be small, but means it is subjected to high forces. &#8220;Most people would use aluminium,&#8221; said Childe. &#8220;Through simulation we designed out as much stress as possible and so we can make the impeller out of carbon fibre-reinforced polymer.&#8221; <\/p>\n<p>A plastic impeller and steel shaft means welding is out of the question. &#8220;Everything in the vacuum cleaner is dependent on bonding,&#8221; said Childe. &#8220;We have had an engineer working for two years on adhesives for the product.&#8221; <\/p>\n<p>The motor has been dubbed DDM (Dyson digital motor) V2. <\/p>\n<p>What was effectively DDM V1 was actually dubbed <strong><strong>X020<\/strong><\/strong> and is the switched reluctance designed used in the company&#8217;s Airblade hand dryer. <\/p>\n","protected":false},"excerpt":{"rendered":"<p>Dyson has gone to 104,000rpm brushless DC technology to combine efficiency and manufacturability in its latest handheld vacuum 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