The design of a high torque brushless DC motor to replace the induction motor and worm gear for valve actuators is described. Minimum motor cost, short axial length and low electronics rating are achieved by selection of open slots and coils wound on bobbins. First and second harmonic designs are compared, with either 2 or 4 magnet poles facing 3 teeth. As well as being cheaper from having fewer coils, the second harmonic design is found to be superior in having lower copper loss at peak torque. The peak tangential force density across the gap was 5.8 x 104 N/M2.Measurements are reported on 75 Nm and 150 Nm peak torque prototypes, which are intended to "run" at 180 rpm and at 20 Nm and 40 Nm respectively. Though 36 pole motors, their no load loss would be sufficiently low for higher speed operation, even to around 2000 rpm. Successful operation as an actuator was observed on a valve.
I. INTRODUCTIONElectric actuators are used in many industries to operate valves for fluid flow control. In the power generation industry in particular, each boiler unit requires dozens of actuators for the control of high pressure and high temperature steam and water. Common valve types are quarter-turn butterfly valves and globe valves. Globe valves have an axisymmetric plug which moves linearly between two end-stops or "seats", via the screw action of the threaded valve stem within the threaded valve body, with typically tens of turns required for full travel.A typical commercial multi-turn valve actuator features a fixed speed induction motor driving a worm gear of high gear ratio, e.g. 40:1. Problems associated with the gearing include its size, low efficiency (typically 40°/O), need for lubrication service, and wear. A drawback for the actuator manufacturer in the use of mains frequency induction motors is that a large number of combinations of motor pole numbers and gear ratios are needed to span the required range of actuator torques and speeds. This paper reports the development of a direct drive brushless DC motor and 3-phase electronic controller to replace the induction motor and worm gear, thus eliminating the gearbox problems and enabling precise, variable speed operation with only a small range of motors. The elimination of the worm gear demands a high torque capability for the brushless DC motor. The emphasis in this paper will be on the design of a motor for high peak torque at low speed. Motors for peak torque actuator ratings of 75 Nm and 150 Nm are described. The project has been mentioned previously [1] but this is its first thorough description outside patent applications.