Code #3744
Industry Overview
An electric motor is a device that converts electrical energy into mechanical energy in the form of rotational force. Its operation is based on the principles of electromagnetism. When a current-carrying conductor is placed within an external magnetic field, it experiences a force that is proportional to the current flowing through the conductor and the strength of the magnetic field. This force causes the conductor to rotate from its original position.
Brushless DC (BLDC) motors are an important category of electric motors that operate without conventional mechanical brushes. The report covers the working principles, construction, components, types, advantages, disadvantages, applications, manufacturing processes, testing procedures, market position, and industry-related aspects of BLDC motors. It also addresses the fabrication of stators and rotors, rotor magnets, housings, end bells, electronic components, assembly, and motor testing. Additional sections cover BIS specifications, plant layout, raw-material suppliers, machinery and equipment suppliers, market information, export and import data, and project economics.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 100 Nos/Day |
| Land & Building (2500 sq.mt.) | Rs. 2.19 Cr |
| Plant & Machinery | Rs. 1.36 Cr |
| Working Capital for 2 Months | Rs. 10.56 Cr |
| Total Capital Investment | Rs. 14.33 Cr |
| Rate of Return | 21% |
| Break Even Point | 55% |
Content Index
- INTRODUCTION
- CLASSIFICATION OR TYPES OF MOTOR
- DC MOTOR
- BRUSHLESS DC MOTORS WORK
- WORKING OF DC MOTOR
- ADVANTAGES OF DC MOTORS:
- DISADVANTAGES OF DC MOTORS
- TYPES OF DC MOTORS:
- THE DC MOTORS ARE DIVIDED MAINLY TO:
- BRUSHLESS D.C MOTOR
- WORKING PRINCIPLE AND OPERATION OF BLDC MOTOR
- CONSTRUCTION OF BLDC MOTOR
- ROTOR
- HALL SENSORS
- TYPES OF BRUSHLESS DC MOTORS
- INNER ROTOR DESIGN
- OUTER ROTOR DESIGN
- ADVANTAGES OF BRUSHLESS DC MOTOR
- DISADVANTAGES OF BRUSHLESS DC MOTORS
- DISADVANTAGES OF BLDC MOTOR
- USES AND APPLICATIONS OF BLDC MOTORS
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- MANUFACTURING PROCESS OF BRUSHLESS D.C MOTOR
- FABRICATION PROCESS OF STATOR
- 1. STAMPING
- 2. STACKING
- 3. SLOT INSULATION
- 4. WINDING
- 5. PREPPING
- FABRICATION PROCESS OF ROTOR
- ROTOR MAGNET
- 1. SHAFT MACHINING
- 2. HUB MACHINING
- 3. HUB MAGANET GLUING
- 4. BEARING PRESSING
- FABRICATION OF HOUSING AND EEND BELL MANUFACTURING
- ELECTRONICS MANUFACTURING:
- ASSEMBLING OF BLDC MOTOR
- TESTING OF BLD.C MOTOR
- CLASSIFICATION OF TEST
- 1. TYPE TESTS
- 2. ROTUNE TESTS
- 3. PERFORMANCE TEST
- (A) NO LOAD TEST
- (B) REDUCED VOLTAGE RUNNING UP TEST
- (C) OPEN CIRCUIT VOLTAGE RATIO 'REST FOR WOUND
- (D) ROTOR (SLIP RING) MOTORS
- (E) LOCKED ROTOR TEST
- (F) FULL LOAD TEST
- (8) MARKING
- MARKET POSITION
- INCREASING DEMAND FOR HVAC APPLICATIONS DRIVES THE GLOBAL BRUSHLESS DC MOTORS MARKET
- THE FOLLOWING ARE THE MAJOR OBJECTIVES OF THE STUDY.
- BRUSHLESS DC (BLDC) MOTORS MARKET
- THE GLOBAL BRUSHLESS DC MOTORS MARKET IS CLASSIFIED INTO FOLLOWING CATEGORIES:
- BY POWER CAPACITY
- BY DESIGN
- BY REGIONA
- ELECTRIC DC MOTOR MARKET
- TYPE INSIGHTS
- VOLTAGE INSIGHTS
- END-USE INSIGHTS
- REGIONAL INSIGHTS
- COMPETITIVE INSIGHTS
- IGARASHI MOTORS INDIA LTD MANAGEMENT DISCUSSIONS.
- AUTOMOTIVE MARKET
- AUTOMOTIVE TECHNOLOGY & CONSUMER TRENDS
- ACTUATORS & MOTORS
- ACTUATORS & MOTORS – TAM (TORQUE ACTUATOR MOTOR)
- ACTUATORS & MOTORS – CAM (COMFORT ACTUATOR MOTOR)
- LEARNINGS DURING THE YEAR
- BRUSHLESS DC MOTORS – BLDC:
- NIL SPILL
- MANUFACTURING TECHNOLOGY
- NEW INFRASTRUCTURE
- PERFORMANCE 2017-18
- RISKS & CONCERNS
- SEGMENT WISE/ PRODUCT WISE PERFORMANCE
- INTERNAL CONTROL SYSTEMS & ADEQUACY
- MATERIAL DEVELOPMENTS IN HUMAN RESOURCES
- INDIA ELECTRIC MOTORS MARKET TO CROSS $ 2.25 BILLION BY 2023
- INDIA ELECTRIC MOTORS MARKET TO CROSS $ 2.25 BILLION BY 2023
- “INDIA ELECTRIC MOTORS MARKET”
- DETAILED EXPORT DATA OF DC MOTOR BRUSHLESS
- DETAILED IMPORT DATA OF BLDC MOTOR
- PLANT LAYOUT
- MANUFACTURERS/SUPPLIERS OF BLDC MOTOR
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF CRNGO SILICON STEEL
- SUPPLIERS OF INSULATION KRAFT PAPER
- SUPPLIERS OF COPPER WINDING WIRE
- SUPPLIERS OF PERMANENT MAGANET
- SUPPLIERS OF MOTOR SHAFT
- SUPPLIERS OF D.C MOTOR PARTS
- SUPPLIERS OF BLDC HALL SENSOR CONTROLLER
- SUPPLIRS OF PLANT AND EQUIPMENTS
- MOTOR MAKING MACHINES
- SUPPLIERS OF PRECISION MEASURING TOOLS
- SUPPLIERS OF ELECTRICAL MEASURING AND TESTING EQUIPMENT
- ELECTRICAL PANEL
- COOLING TOWER
- EFFULENT TREATMENT PLANT (ETP PLANT)
- AIR POLLUTION CONTROL EQUIPMENTS
- AIR CONDITIONING EQUIPMENTS
- AIR COMPRESSORS
- PLATFORM WEIGHING MACHINE
- MATERIAL HANDLING EQUIPMENTS
- FIRE FIGHTING EQUIPMENTS
- SHOT BLASTING MACHINE
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
A brushless DC motor is an electric motor that converts electrical energy into rotational mechanical energy without using conventional mechanical brushes. Its operation relies on electromagnetic interaction between the magnetic field and current-carrying conductors, while electronic commutation controls the motor's operation. The report covers BLDC motor construction, including the rotor, stator, Hall sensors, magnets, shaft, hub, bearings, housing, and electronic components. These motors can be designed in different configurations, including inner-rotor and outer-rotor designs.
A BLDC motor works by using electromagnetic forces and electronic commutation to produce continuous rotation. Current supplied to the motor windings interacts with the magnetic field associated with the rotor, generating torque and causing the rotor to turn. Electronic control circuitry switches the energization of the windings in the required sequence. Hall sensors may be used to provide rotor-position information to the controller. The report therefore covers both the electromagnetic operating principle and the electronic and mechanical components required for BLDC motor operation.
The main components of a BLDC motor include the stator, rotor, rotor magnets, shaft, hub, bearings, housing, end bell, windings, and electronic control components. Hall sensors can also be incorporated to detect rotor position for electronic commutation. The report describes separate fabrication processes for the stator and rotor, including stamping, stacking, slot insulation, winding, shaft machining, hub machining, magnet gluing, and bearing pressing. Proper integration of mechanical, magnetic, electrical, and electronic components is important for reliable motor operation.
BLDC motor manufacturing involves fabrication of the stator and rotor, production of the housing and end bell, electronics manufacturing, assembly, and testing. Stator fabrication can include stamping, stacking, slot insulation, winding, and prepping. Rotor fabrication includes shaft and hub machining, magnet installation, and bearing pressing. The completed mechanical and electronic components are then assembled and subjected to specified tests. The report also identifies manufacturing equipment, precision measuring tools, electrical testing equipment, and supporting plant facilities.
BLDC motor testing can include type tests, routine tests, and performance tests. The report specifically lists no-load testing, reduced-voltage running-up testing, open-circuit voltage ratio testing for wound rotor applications, locked rotor testing, and full-load testing. These tests are intended to examine different operating and performance characteristics of the motor. Appropriate electrical measuring and testing equipment is required, and the testing program should be aligned with the applicable specifications and the intended application of the motor.
BLDC motors are used across applications that require controlled rotational motion and efficient motor operation. The report discusses applications associated with HVAC systems, automotive technology, actuators, and other motor-driven equipment. Their use depends on factors such as required torque, speed, control method, motor configuration, operating environment, and system design. BLDC motors can be configured for different applications through appropriate selection of rotor design, power characteristics, electronic control, and mechanical construction.
A BLDC motor manufacturing plant requires production, testing, material handling, utilities, and supporting infrastructure appropriate to its manufacturing process. The report identifies motor-making machines, precision measuring tools, electrical measuring and testing equipment, electrical panels, cooling towers, air compressors, material handling equipment, fire-fighting equipment, and shot blasting machines. It also includes suppliers for raw materials and components such as silicon steel, insulation kraft paper, copper winding wire, permanent magnets, motor shafts, DC motor parts, and Hall sensor controllers.
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