Combined commutation optimisation strategy for brushless DC motors with misaligned hall sensors

Brushless direct current (BLDC) motors with Hall sensors are widely used in various applications. Installation errors for Hall sensors may lead to inaccuracy regarding the commutation position, which can lower the motor efficiency. To improve the performance of the BLDC motors, this study presents a new combined commutation optimisation strategy for obtaining the ideal commutation position. The new strategy consists of two procedures: averaging the misaligned Hall signals and compensating for the averaged Hall signals. A mathematical relationship between the DC-link current and overall deviation error was established, and a proportional-integral controller was built to compensate the commutation position. Several experiments were conducted to verify the effectiveness of the new combined commutation optimisation strategy.