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MELCON BLDC PCBA – Advanced DC Brushless Motor Control

A DC brushless motor (BLDC) is a typical mechatronic system composed of the motor body and an electronic driver. The stator winding of the motor is usually designed in a three-phase symmetrical star connection, very similar to a three-phase asynchronous motor.

How It Works

The driver is built from power electronic devices and integrated circuits. Using rotor position signals from the motor’s position sensor, the driver triggers each power transistor in the drive circuit. The controller then performs orderly commutation to generate continuous torque. It accepts start, stop, and brake commands to manage motor operation, processes position sensor feedback for commutation logic, and handles speed commands with feedback signals for closed-loop control. Additionally, it provides fault protection and system status display.

This allows the BLDC motor to deliver:

• Fast response and large starting torque.

• Rated torque performance from zero speed to rated speed.

• Smooth operation with advanced microprocessor-based two-axis (d-q) control, enabling AC motor regulation similar to DC motor performance.

As mechanically powered systems are phased out, BLDC motors are increasingly replacing them, thanks to higher efficiency, reliability, and compactness. Their adoption is expanding rapidly across home appliances and consumer electronics, where efficiency standards are becoming stricter and advanced motor control is essential.

Melcon BLDC PCBA Advantage

The Melcon BLDC PCBA, developed in technical partnership with Power Integrations and Holtek Microcontrollers, integrates a half-bridge motor driver family with advanced high-speed control.

Key features include:

• High- and low-side FREDFETs (Fast Recovery Diode Field Effect Transistors) for ultra-fast switching.

• Integrated lossless current sensing, improving efficiency and protection.

• Efficiencies above 98.5% in BLDC drive applications up to 90–150W.

• Suitable for kitchen hoods or air-conditioning compressors (1-ton, ~750W motors).

• Distributed thermal footprint architecture, eliminating the need for heatsinks and thereby reducing system size, cost, and weight.

With these innovations, the Melcon BLDC PCBA delivers superior performance, reliability, and cost-effectiveness, making it an ideal choice for next-generation consumer and industrial applications.

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